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Lissmac MULTICUT 570 Gearbox M Operating Manual
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Lissmac MULTICUT 570 Gearbox M Operating Manual

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EN
OPERATING MANUAL
FLOOR SAW
MULTICUT 570
LISSMAC Corporation
17 Route 146
Mechanicville, NY 12118, USA
Telephone 518-326-9094
Fax 518-326-9098
sales@lissmac-corporation.com
www.lissmac-usa.com
1/99

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Summary of Contents for Lissmac MULTICUT 570 Gearbox M

  • Page 1 OPERATING MANUAL FLOOR SAW MULTICUT 570 LISSMAC Corporation 17 Route 146 Mechanicville, NY 12118, USA Telephone 518-326-9094 Fax 518-326-9098 sales@lissmac-corporation.com www.lissmac-usa.com 1/99...
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  • Page 3 Save this manual for future reference! Distribution and duplication The dissemination or duplication of this operating manual in any form, or the reuse of its contents prohibited, unless permission was given in writing by LISSMAC. Non-compliance is subject to 3/99...
  • Page 4 Limitations The warning and safety notes contained are not exhaustive. Lissmac cannot foresee every potential hazard arising from neglect or misuse. Reasonable safety rules and precautions must be followed as with any other machine, in terms of working methodology and operation.
  • Page 5 The following hazard symbols and safety notes are used: Read the operating manual Explosion hazard Wear hearing protection Entanglement hazard at belt drive Wear safety goggles Cut hazard at rotating tool Wear work gloves High-pressure fluid injection hazard Wear protective helmet Do not use high pressure cleaners Attachment point for crane transports Use by unauthorized persons not permitted...
  • Page 6 As a supplement to this operating manual, additional documentation regarding individual machine components is available by the respective component manufacturer:  HATZ Diesel Engine Operating Manual LISSMAC does not assume responsibility or liability regarding correctness and completeness of third- party documentation. Changes and reservations We are committed to ensuring accuracy and timeliness of the presented operating manual.
  • Page 7 Notes: 7/99...
  • Page 8 1. Features & Benefits ......................10 Table of contents 2. General safety notes ...................... 11 2.1. Principle of intended use ....................11 2.2. General safety measures ....................12 2.3. Personnel Qualification and Responsibilities ..............13 2.4. Safety notes regarding the operating phases ..............13 2.5.
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  • Page 10 1. FEATURES & BENEFITS Industry requirements were implemented in the design of these versatile power pack. Put to the test by industry professionals, this diesel floor saws features impressive price-performance ratio, rugged design, and exceptional ease of operation. • High-performance V-belts for optimal power transmission •...
  • Page 11 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 diamond blade.
  • Page 12 2.2. General safety measures The operating manual must be easily accessible at all times, at the location of the floor saw. In addition to the operating manual, directives for accident prevention and environmental protection, as mandated by applicable national and local requirements are to be followed! Such obligations may include, amongst others, handling of hazardous materials, wearing of personal protective gear, and following of traffic regulations.
  • Page 13 2.3. Personnel Qualification and Responsibilities Only qualified personnel, 18 years of age or older, may operate the floor saw. All operators must be appropriately trained in the operation, and be explicitly authorized in writing by the company to operate the floor saw. Personnel responsibilities pertaining to the operation, set-up, servicing, and repair of the machine must be established and monitored by management.
  • Page 14 2.4.2. Commissioning When fitting the diamond blade, protect your hands from sharp edges. When installing the diamond blade, observe the running direction. The cutting must always be in the direction of travel (down-cut). Visual check of the entire floor saw for any damage and defects. Separate check of the protective devices.
  • Page 15 2.4.4. Maneuvering the floor saw The floor saw may only be relocated when the diamond blade is standing still. Gearbox hast to be set to NEUTRAL for relocating with ground drive. Before leaving the operating position on the floor saw, the Diesel engine must be switched off and the diamond blade must come to a complete stand still.
  • Page 16 2.5.3. 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 regularly. Defects such as loose connections and damage cables must be repaired immediately.
  • Page 17 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 18 3. DEVICE DESCRIPTION 3.1. Designation of machine parts Pos. 1 Handlebars Pos. 9 Gearbox Pos. 2 Control console Pos. 10 Blade guard and Sawblade flange Pos. 3 Air filter Pos. 11 Engine Radiator filler neck Pos. 4 Diesel Tank Pos. 12 Pocket for water supply and ball valve Pos.
  • Page 19 3.2. Technical specifications MULTICUT 570 Gearbox M MULTICUT 570 Gearbox T Max. cutting depth 420 mm (16.7 in) Max. diamond blade diameter 1000 mm (39.4 in) Diamond blade arbor 25,4 mm (1.0 in) Nominal speed 1. gear 800 1/min 1050 1/min Nominal speed 2.
  • Page 20 3.3. Sound power level WARNING Danger of hearing damage Wearing hearing protection is mandatory at sound power level of above 85 dB (A). Wear your personal hearing protection.  The detail defines the volume of the noise relative to the operator's workplace and to the sound power level of the floor saw.
  • Page 21 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 is voided. S≤15 mg/kg Engine Oil Only use HATZ-approved engine oil.
  • Page 22 4.2. Tools (diamond 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 diamond See section 9 Blade Speed blade Storing tools The tools used must be protected from moisture.
  • Page 23 4.3. Refueling WARNING Extremely flammable fuel vapors Risk of serious injury from fire or explosion. Do not refuel with the engine running  Smoking is prohibited during the process.  Remove all sources of ignition.  Do not overfill tank or spill fuel. ...
  • Page 24 5. TRANSPORT 5.1. Transport position WARNING Crush hazard from unsecured machine Personal damage from unintentional position change of the machine or falling of parts. Only transport the floor saws in the transport position  Secure the floor saw at the lashing points ...
  • Page 25 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 26 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 27 6. CONTROL CONSOLE Pos. 1 Diesel Tank filler cap Pos. 9 Ignition switch Pos. 2 Multifunction display Pos. 10 Emergency Stop Button Pos. 3 Engine air filter Pos. 11 Drive lever (forward / reverse) Pos. 4 Radiator filler cap Pos. 12 Switches for raising the frame Pos.
  • Page 28 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 29 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 30 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 31 WARNING Cut hazard form rotating diamond blade Severe cut injuries from to rotating diamond 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 32 7.2. Start preparations NOTICE Cutting without obstacles Damage of articles located in the cutting area or the diamond blade.  Remove all obstacles from the cutting area and  Provide good lighting of the work area. Start preparation The following conditions must be fulfilled in order to use the floor saw safely and as intended: ...
  • Page 33 7.3. Engine starting and stopping Starting set the ignition key to ignition wait until the multifunction display has booted 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 error message will appear:...
  • Page 34 7.4. 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 7.5. Adjusting the operating position Install the handle bars in the most convenient position for the operator.
  • Page 35 7.7. Diamond blade installation and removal WARNING Cut and crush hazard from rotating parts Rotating diamond blade or flange can pull in clothes and sever or body parts. Switch off the engine and remove the ignition key.  Before working on the machine, all parts must be stationary. ...
  • Page 36 Gearbox T Gearbox M NOTICE Diamond blade installation Appropriate diamond blades must be used, with the correct shear pin size and the correct arbor diameter to fit on the shaft. Ensure flange surfaces to be clean before installing the diamond blade. The diamond blade has to rest evenly on the flange.
  • Page 37 7.8. Change from right to left cut 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. Only perform this work with the engine turned off and pulleys standing still.
  • Page 38 7.9. 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.  Do not open or remove the belt guard or touch the v-belt while it rotates. Only perform this work with the engine turned off and pulleys standing still.
  • Page 39 7.10. 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 40 NOTICE Belt replacement Do not mix different belt types or manufacturers. We strongly recommend exchanging belts as a full matching set. Especially mixing used and new belts will reduce service life of new belts by half. 7.11. Gear selection NOTICE Change gears only at standstill The four gears allow the tool’s speed setting to be adjusted to each diamond blade diameter and aggregate to be cut.
  • Page 41 7.12. Cutting operation WARNING Ejected parts hazard If the diamond 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. ...
  • Page 42 Cutting 1. Place drive lever in neutral start positon 2. Start engine with ignition key (Pos. 9). 3. Lower pointer with rope (Pos. 15) and maneuver flor saw into position 4. Adjust cutting shaft speed with engine throttle (Pos. 5) check shaft RPM in the multifunction display (Pos.
  • Page 43 7.13. Maneuvering the floor saw WARNING Cut hazard from rotating diamond blade By touching the rotating diamond 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 44 7.14. 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  Floor saw shutdown 1. Raise diamond blade to have ample ground clearance. 2.
  • Page 45 7.16. Service compartment Pos. 1 Reservoir for cutting shaft lifting unit (HV68) Hydraulic oil fill level can only be checked correctly when the machine is lowered completely. Pos. 2 Battery 45/99...
  • Page 46 7.17. Fuses 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 30 A 10 A Fuel pump 15 A Power supply 40 A Glow plug T15/50 control unit...
  • Page 47 7.18. Battery 12V - 650A cold cranking amps (DIN H5 / EN LN2 / BCI 47 - 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.
  • Page 48 7.20. Draining gearbox cooling water NOTICE 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. If there is no ball valve installed use pressurized air to blow out the water. Option T Option M Sequence...
  • Page 49 7.22. 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 50 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 51 8.2. 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 52 8.3. 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. Both sides, until grease escapes.
  • Page 53 8.4. Transaxle oil change WARNING Crush hazard from active drive unit Body parts and clothing may become entangled or pulled in if the drive unit is active. Danger of cut and crush injuries including dismemberment. Remove ignition key before performing any service on the machine ...
  • Page 54 6. Fit the drain plugs with new sealing washers and screw them back in. 7. Fill the extension tank with 2.6 qt./US liq (2.5l) This process takes some time to complete, as the oil spreads slowly inside the housing and the oil cannot be filled in one go.
  • Page 55 8.5. Hydrostat Ölwechsel WARNING Crush hazard from active drive unit Body parts and clothing may become entangled or pulled in if the drive unit is active. Danger of cut and crush injuries including dismemberment. Remove ignition key before performing any service on the machine ...
  • Page 56 Gearbox T Sequence Gearbox M Rest the machine safely and horizontally on trestles. Remove the cover of the expansion tank. (Pos. 1) Place the collection container underneath. Remove drain plug C and drain oil. Remove screw plug B. Screw in drain plug C again. Fill in oil until oil emerges from port B.
  • Page 57 8.6. Particular maintenance NOTICE Storing the 4-speed gearbox During prolonged storage or periods of nonuse, internal components will lose their lubrication film. Start the machine or manually turn the gears at least once every 6 months to reestablish the  protective lubricating film.
  • Page 58 8.7. Regeneration of the Diesel Particulate Filter (Stage V Engine only) 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 59 Securely park floor saw in an open space with ample distance to flammable objects. Preparation Remove Saw blade. Install blade guard. Place wheel chocks to immobilize machine. Set engine RPM (Pos. 5) to idle. Initiate The engine coolant temperature must be above 75°C (167°F). Set drive lever (Pos.
  • Page 60 8.8. 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 61 8.9. 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 61/99...
  • Page 62 9. BLADE SPEED Circumferential speed m/s Diamond blade diameter mm for asphalt for concrete All tools in the area of the diamond tools are marked in color. The tools differ depending on the application purpose and area of application. The parameters must be correct in order to achieve the best results. The optimum cutting performance can be determined with this diagram.
  • Page 63 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 64 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 wet-cutting joints in concrete or asphalt using a diamond tipped tool.
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  • Page 69 12. APPENDIX A: ERROR CODE LIST HATZ 69/99...
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