Lissmac MULTICUT 550 / 600 Owner's manual

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OPERATING MANUAL

FLOOR SAW

MULTICUT 550 GH

MULTICUT 600 G / SG

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

EN

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Legal notice This operating manual is valid for:

LISSMAC floor saw

 MULTICUT 550 G / GH

 MULTICUT 600 G / SG

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

Original operating manual

Issue date: 08-2020

Save this manual for future reference!

Distribution and duplication This operating manual must not be disclosed or reproduced in any form or its contents used without

written permission to do so.

design or design patent registration.

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BASIC SAFETY INFORMATION

Warning notes and symbols in this manual

SIGNAL WORD

Type and source of danger

Consequence of non-compliance.

 Action to avert the danger

The signal word after the hazard symbol indicates the level of danger:

DANGER

This signal word indicates an extremely dangerous situation. If the situation is not avoided,

the consequence will be fatal injuries. The hazard symbol may give details of the danger.

WARNING

This signal word indicates a potentially dangerous situation. If the situation is not avoided, the

consequence may be fatal or serious injuries.

The hazard symbol may give details of the danger.

CAUTION

This signal word indicates a dangerous situation. If the situation is not avoided, the

consequence will be medium and minor injuries. The hazard symbol may give details of the

danger.

NOTICE

This signal word indicates a situation which may present a danger for property. If the situation

is not avoided, the consequence will be property damage. This signal word is shown without a

hazard symbol.

Important information is marked with an "i".

Request for the operator to take action:

The specified sequence of the action steps facilitates the proper and safe handling of the

machine.

 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.

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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

Cutting hazard at the rotating tool

Wait for all parts to stop

Do not relocate the machine with rotating tool

Extremely flammable fuel vapors

Warning of crushing hazard.

Ejected parts hazard

Warning of suspended loads

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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

Instruction for damage prevention.

Lashing point for vehicle transport

Only transport in an upright position

Sound power level of the machine

Visual check

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OPERATING MANUAL

Preface This operating manual is designed to make it easy to familiarize yourself with the machine and use it

for its intended purpose.

The operating manual contains important information on how to operate the machine safely, properly

and economically. Compliance with it will help to avoid dangers, repair costs and downtimes and

increase the reliability and service life of the machine.

The operating manual is to be supplemented by instructions due to existing national regulations for

accident prevention and environmental protection.

The operating manual must be available at the location of the machine at all times.

The operating manual must be read and used by everybody who undertakes work on the machine, for

example:

 Operation, including setting, troubleshooting whilst operating, removal of production waste,

care, disposal of media and consumables

 Maintenance (servicing, inspection and repair) and/or

 Transport

In addition to the operating manual and the binding regulations for accident prevention which apply in

the user's country and at the place of use, the acknowledged rules for safe and correct working

practice must also be observed.

Tools required A tool in the form of a saw blade is required for operating the floor saw. These tools can be purchased

from the manufacturer.

Further documents 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. To keep our

technological lead over our competitors, it may be necessary to make modifications to the product and

its operation without prior notice. We cannot accept any liability for faults, failures and resulting

damage.

Target group These operating instructions are aimed at semi-skilled and trained personnel in the fields of structural

mechanics, concrete cutting technology, road construction, and civil engineering.

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Notes:

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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. Note relating to special types of danger .........................................................................16

2.6. Transport .........................................................................................................................17

2.7. Packaging and storage ....................................................................................................18

2.8. Environmental protection ................................................................................................18

2.9. Waste disposal ................................................................................................................18

3. Device description ......................................................................................................... 19

3.1. Designation of machine parts ..........................................................................................19

3.2. Technical specifications ..................................................................................................20

3.3. Sound power level ...........................................................................................................21

3.4. Exhaust fumes .................................................................................................................21

3.5. Hand-Arm Vibration .........................................................................................................22

4. Comissioning .................................................................................................................. 23

4.1. Consumables ...................................................................................................................23

4.2. Tools (saw blade) ............................................................................................................24

4.3. Water pump.....................................................................................................................25

4.4. Refueling .........................................................................................................................26

4.5. Saw blade installation / change (tool) .............................................................................27

4.6. Checking v-belt tension ...................................................................................................29

4.7. Replacing and tensioning v-belts ....................................................................................30

5. Transport......................................................................................................................... 33

5.1. Transport position ...........................................................................................................33

5.2. Relocating by crane .........................................................................................................34

5.3. Tie down for transport .....................................................................................................35

6. Control Desk ................................................................................................................... 36

6.1. Multifunction display .......................................................................................................37

7. Operation ........................................................................................................................ 39

7.1. Safety ..............................................................................................................................39

7.2. Parking lock .....................................................................................................................41

7.3. Start preparations ...........................................................................................................42

7.4. Weight plates (optional) ..................................................................................................42

7.5. Adjusting lowering speed of saw arm .............................................................................43

7.6. Adjusting the handlebars ................................................................................................43

7.7. Gear selection .................................................................................................................44

7.8. Switching from Up-cut to down-cut.................................................................................45

7.9. Engine starting and stopping ...........................................................................................46

7.10. Toe in adjustment ..........................................................................................................47

7.11. Adjusting the cutting depth stop ...................................................................................47

7.12. Cutting operation ...........................................................................................................48

7.13. Maneuvering the floor saw ...........................................................................................50

7.14. Floor saw shut-down .....................................................................................................51

7.15. Conversion from left- to right-cutting ............................................................................52

7.16. Service compartment .....................................................................................................53

7.17. Hydraulic unit (Option SGH) ..........................................................................................54

7.21. Draining gearbox cooling water ....................................................................................57

7.22. Cleaning the water pump ..............................................................................................57

7.23. Checking engine oil level ...............................................................................................58

7.24. Cutting with open blade guard ......................................................................................59

8. Maintenance .................................................................................................................. 60

8.1. Service .............................................................................................................................60

8.2. Tensioning the drive chain ..............................................................................................61

8.3. Changing engine oil .........................................................................................................62

8.4. Grease points ..................................................................................................................63

8.5. Transaxle oil change ........................................................................................................64

8.6. Troubleshooting ...............................................................................................................67

8.7. Torque values for screw connections ..............................................................................68

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8.8. Maintenance plan ...........................................................................................................69

9. Tools ................................................................................................................................ 70

10. Warranty ....................................................................................................................... 71

11. Circuit diagram ............................................................................................................. 73

12. APPENDIX A: ERROR CODE LIST HATZ ....................................................................... 77

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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

 Warp resistant sheet metal design

 Compact and well-balanced chassis for easy maneuvering

 Extremely low center of gravity for precise cuts

 Very good straight-cutting properties due to tunable rear axle

 Electro-hydraulically controlled saw blade lift

 Height adjustable handlebars

 Hinged split blade guard for near-wall cuts comes as standard

 Fast left- to-right cut conversion

 Easy access to maintenance components (Air filter, battery, oil reservoir and fuel filter)

 Parking lock, operating hours counter and free-wheeling come as standard

Option SG

(3-speed gear box)

Option GH

(2-speed gear box with hydraulic system)

Option G

(2-speed gear box)

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2.

GENERAL SAFETY NOTES

2.1. Principle of intended use

The manufacturer and supplier does not assume any liability in case of incorrect or unintended use.

The machine must not be modified by anybody other than the manufacturer. Changes due to

attachments or conversions on the floor saw require the written approval of the manufacturer.

The machine is built according to the state of the art and the recognized safety-related rules.

Nevertheless its use may result in dangers of injury and death of the user or third parties or adverse

effects to the machine and other property.

The machine must only be used if it is in technically perfect condition and for its intended use, with an

awareness of safety and potential dangers and as set out in the operating manual. In particular, faults

which may adversely affect its safety must be rectified immediately.

Intended use The LISSMAC floor saw belongs to the floor cutting-off machines 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. The operator must remain behind the handlebars as

long as the machine is running. Any other use above and beyond is considered unintended use.

Intended use also includes compliance with the operating manual and compliance with the inspection

and maintenance manual.

Unintended use Foreseeable misuse / unintended use:

 Cutting without blade guard

 Cutting without water

 Cutting on steep slopes

 The cutting of narrow radii

 Cutting wood, plastics or metal

(except for reinforced concrete)

 Design modifications which alter the safety or design type of the floor saw

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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.

The personnel assigned with activities at the machine must have read and understand the operating

manual before starting work, and here particularly the chapter safety notes. This particularly applies

to personnel who only work on the machine occasionally, for example setting and maintenance

personnel.

Regularly check that the procedures used by the personnel are safe and show an awareness of the

dangers and that they are following the instructions in the operating manual.

Always use the required and prescribed personal protective equipment.

Observe all safety and danger notes at the floor saw and keep them in readable condition. Replace

any damaged or illegible safety information and warnings.

With safety-related changes of the machine or its operational behavior, shut the machine down

immediately and mark it accordingly. Report the fault to the responsible body/person.

Do not make any changes, by attachment or conversions without written permission of the

manufacturer. The instructions provided by the tool manufacturer must be given due consideration.

Use only checked original spare parts of the manufacturer.

Adhere to prescribed periods for inspection or those specified in the operating manual.

For the implementation of maintenance measures, workshop equipment appropriate for the work is

absolutely necessary.

Machines with internal combustion engines must not be used in closed rooms.

Always obtain detailed information on underground cables in the cutting area and take appropriate

precautions before cutting.

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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.

Specify the responsibilities of the personnel for operating, setting up, maintenance and repairs.

Ensure that only authorized personnel works on the machine.

The operator must wear personal protective equipment such as safety shoes, gloves, safety goggles

and hearing protection, which comply with the safety regulations.

Expel persons not working with the machine from the work area. Cordon off the working area if

necessary.

The operator must ensure with all movements of the floor saw that he does not endanger himself and

other persons. All obstructions which hinder the work procedure or the implementation of the machine

must be cleared at the place of work.

Work on the electrical equipment on the machine may only be carried out by a qualified electrician or

by trained personnel under the management and supervision of a qualified electrician and in

compliance with the electronic regulations.

The operator must be named as the person responsible for traffic-related regulations and make it

possible for him to reject unsafe instructions by third parties.

Only allow personnel being trained, instructed or those completing an apprenticeship to work on the

machine under the constant supervision of an experienced person.

2.4. Safety notes regarding the operating phases

2.4.1. Transport, assembly and installation

Transport, set-up and installation on/with the floor saw must only be carried out in transport position.

The floor saw must be secured against rolling away.

Transport, set-up and installation on/with the floor saw must only be carried out with the saw blade

removed and the motor switched off.

Use a crane to load and unload the floor saw, taking into account the maximum operating weight of

the machine.

Transport may only take place, if all parts on the machine are secured and falling off of individual

parts is impossible.

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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.

Supply water for saw blade cooling.

Smoking is prohibited when refueling the internal combustion engine.

Particular care should be taken during refueling. Engine parts that became hot during operation pose a

fire hazard.

Fuel must only be stored in approved containers.

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.

2.4.3. Operation

Do not use any unsafe method of working.

Take measures to ensure that the floor saw is only used if it is safe and in functional condition.

Check the floor saw at least once per shift for external signs of damage and defects. Notify the

responsible place/person immediately when changes have occurred (including the operational

behavior). If necessary, shut down the machine immediately and secure it to prevent it being switched

on again.

If the floor saw malfunctions, shut it down immediately and secure it. Have faults corrected

immediately. Electrical installation work may only be carried out by trained electrical personnel.

Only use suitable and checked tools.

To protect against acceleration, the depth adjustment of the saw blade must be moved slowly and in

steps into the ground. Any contact with the rotating tool must be avoided. Keep a safety distance of

1.5m to the saw blade.

Cutting without the blade guard or drive belt cover is prohibited.

The operator must be protected from rotating parts.

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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.

2.4.5. Special work while using the machine

Observe the adjustment, maintenance and inspection work and intervals specified in this operating

manual including the details for replacing parts/ parts of the equipment. These activities may only be

accomplished by authorized technical personnel.

When the floor saw has been shut down completely for maintenance and repair work, it must be

secured and marked to prevent it from accidental activation.

Before cleaning, cover and seal all openings, into which no cleaning agent may penetrate for safety

and/or function reasons. Electric motors, switches and plug connectors are at particular risk. Remove

the covers/masking tape completely after finishing the cleaning work.

Always retighten all screw connections loosened during maintenance and repair work.

If the disassembly of safety devices is necessary for setup, maintenance and repair, they are to be

reassembled and checked immediately after conclusion of maintenance or repair work.

Never use a rotating tool, with a maximum speed rating lower than the rated speed of the machine.

2.5. Note relating to special types of danger

2.5.1. Dangers for the operator from the machine

Before leaving the operating position on the floor saw, the internal combustion engine must be

switched off and the saw blade must be stationary.

The internal combustion engine of the floor saw must only be used as intended:

Propel the floor saw and drive the saw blade.

The outlet of the exhaust pipe must always point away from the operator. Do not inhale exhaust fumes.

The exhaust pipe gets hot during operation. Avoid contact and wear personal protective equipment.

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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. The machine must be tagged-

out to prevent accidental startup.

2.5.3. Dust

With work in confined spaces, observe existing national regulations, if necessary.

To prevent airborne dust and provide cooling during cutting, the saw blade must be continuously

sprayed with water. Dry cutting is prohibited. Do not eat, drink or smoke in the work area.

2.5.4. Noise

See section 3.3

2.5.5. Exhaust fumes

Machines with internal combustion engine must not be operated indoors or in confined spaces.

2.6. Transport

Lifting gear of sufficient load-bearing capacity must be used when transferring by crane. Check lifting

gear beforehand for any damage.

Appoint a capable signalperson for the lifting operation.

Only lift the floor saw as described in the operating manual using lifting gear.

Only use a suitable transport vehicle with an adequate load-bearing capacity.

Secure the machine properly in compliance with the regulations. Use suitable lashing points.

The floor saw drive must be switched off even for a minor relocation.

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2.7. Packaging 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.

Do not start the machine if it is damaged. Damaged cables and plug connectors also pose a safety risk

and must not be used. Contact the manufacturer immediately for repair.

If the machine is not operated immediately after unpacking, it must be protected against humidity and

dirt.

2.8. Environmental protection

Packaging material, cleaning products, used or residual media and unpacked wearing parts such as drive

belts or engine oil must be recycled in accordance with the national environmental protection

regulations in force at the place of use.

2.9. Waste disposal

When the device reaches its end of life, particularly if it starts to malfunction, render it inoperable.

Dispose of the device according to the national environmental regulations. Electrical waste may not be

disposed of together with household waste. Deposit the end-of-life device at a central waste collection

center.

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3.

DEVICE DESCRIPTION

3.1. Designation of machine parts

Pos. 1 Handle bars

Pos. 2 Emergency Stop button

Pos. 3 Air filter

Pos. 4 Lifting eye

Pos. 5 Diesel engine

Pos. 6 3-speed-gearbox (*SG option)

Pos. 7 Pointer

Pos. 8 Blade guard

Pos. 9 Chassis

Pos. 10 Drive axis (Hydrostat)

Pos. 11 Water pump with ball valve

2 3 4 5

7

9

10

11

1

6*

8

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3.2. Technical specifications

MULTICUT 550 GH MULTICUT 600 G / SG

Max. cutting depth 415 mm (16.3 in) 515 mm (20.2 in)

Max. saw blade diameter 1000 mm (39.4 in) 1200 mm (47.2 in)

Saw blade arbor 35 mm (6x M12 –TK 120 mm) 25,4 or 35 mm (6x M12 –TK 120 mm)

Blade flange Ø 150 mm

Nominal speed 1. gear 970 1/min (1550 1/min) 970 1/min (1550 1/min) 950 1/min

Nominal speed 2. gear 1550 1/min (2500 1/min) 1550 1/min (2500 1/min) 1620 1/min

Nominal speed 3. gear - - 2450 1/min

Engine HATZ 4-Cylinder

Turbodiesel / EU97/68 IIIA

HATZ 4-Cylinder

Turbodiesel / EU97/68 IIIB & EPA Tier IV

Power (kW/PS) 34 kW / 46,2 PS (45,6 HP) 55 kW / 74,8 PS (73,7 HP)

Fuel type Diesel

Fuel tank size 32 Liter (8.4 gal)

Forward drive speed Hydrostat stepless 0-50 m/min

Reverse drive speed Hydrostat stepless 0-25 m/min

Saw blade lifting mechanism Electro-hydraulic

Saw blade drive V-belt

Weight 950 kg ( 2095 lbs) 930 kg (2050 lbs) 1070 kg (2360 lbs)

Length / Width / Height 1995 / 1030 / 1720

Option GH

(2-speed gear box with hydraulic system)

Option G

(2-speed – requires changing belt setup)

Option SG

(3-speed gear box)

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Lissmac MULTICUT 550 / 600 Owner's manual

Lissmac MULTICUT 550 / 600 Owner's manual

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