Lissmac Grooving Anbausatz Owner's manual

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OPERATING MANUAL

GROOVING-UNIT

LISSMAC Maschinenbau GmbH

Lanzstrasse 4

D-88410 Bad Wurzach

Telephone +49 (0) 7564 / 307 - 0

Fax +49 (0) 7564 / 307 - 500

lissmac@lissmac.com

www.lissmac.com

EN

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Imprint This operating manual is for:

LISSMAC

• Grooving Unit

Company headquarters:

LISSMAC Maschinenbau GmbH

Lanzstraße 4

D - 88410 Bad Wurzach, Germany

Phone: +49 (0) 7564 / 307 – 0

Fax: +49 (0) 7564 / 307 – 500

lissmac@lissmac.com

www.lissmac.com

Original operating manual

Issue date: 06-2020

Save this manual for future reference!

Distribution and duplication of this manual in any form, or use of the content are prohibited unless

permitted in writing.

design patents.

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GENERAL SAFETY NOTES

Warning notices and symbols in this manual

SIGNAL WORD

Warning sign

Type and source of the hazard

Consequence of non-compliance.

 Action to avert the danger

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

DANGER

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates information considered important but not hazard related.

General information is marked with this icon.

Call for action Actions required for the safe handling of the machine:

1. Actions that require to be performed in the given order.

 Actions that are not required to be performed in a certain order.

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.

For California residents: WARNING: Operating, servicing and maintaining this machine can expose you to chemicals

and compounds including engine exhaust, carbon monoxide, benzene, phthalates, and lead,

which are known to the State of California to cause cancer and birth defects or other

reproductive harm. For more information go to www.P65Warnings.ca.gov.

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Warning signs and safety notices:

Read the operating manual

Wear hearing protection

Wear safety goggles

Wear gloves

Wear a protective helmet

Wear safety work boots

Wear suitable work clothes and wash dusty clothes

Wear a dust mask

Suspended loads

Danger of cuts and amputation through rotary grinding tools

Wait for all parts to stop moving.

Danger due to ejected parts

Risk of cuts on rotating tool

Hot surfaces

Suffocation hazard from of toxic exhaust fumes

High-pressure fluid injection hazard

Do not relocate the machine while the tool is rotating

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No access or use by unauthorized persons

Do not use high-pressure cleaners

Hazardous material: fine silica dust

Do not perform maintenance while the engine is running

Instructions for avoiding damage to the equipment

Visual inspection

Spray-on grease

Grease gun

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OPERATING MANUAL

Preface This operating manual makes it easier to become acquainted with the machine and make full use of it

as intended.

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

and economically. Following it will help to prevent hazards, avoid repair costs and downtimes, and

increase the reliability and service life of the machine.

The operating manual should be supplemented by instructions based on existing national accident

prevention and environmental protection provisions.

The operating manual must be constantly available at the place of use of the machine.

The operating manual must be read by every person who works with or on the machine and the

provided instructions must be followed, e.g.:

 operation, including set-up, rectification of faults during the work routine, removal of production

waste, maintenance, disposal of operating and auxiliary materials

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

 Transportation.

In addition to the operating manual and the binding accident prevention regulations applicable in the

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

must also be observed.

Required tool: A tool in the form of a saw blade is required to operate the floor saw. These tools can be purchased

from the manufacturer.

Further Documentation In addition to this operating manual, further documentation is available from the respective

manufacturer of individual machine components:

Floor saw operating manual

Suction unit operating manual

Changes and reservations We strive to keep this operating manual correct and up to date. In order to maintain our technological

advance, it may be necessary to make changes to the product and its operation without advance

notice. We assume no liability for disruptions, downtime and damages that thereby result.

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

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

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Table of contents

1. Properties & Advantages ................................................................................................ 9

2. General Safety ............................................................................................................... 10

2.1. Intended use policy ......................................................................................................... 10

2.2. Organizational measures ................................................................................................. 11

2.3. Choice of personnel and qualifications; fundamental obligations .................................. 12

2.4. Safety notices regarding the operating phases............................................................... 12

2.4.1. Transport and installation ...................................................................................... 12

2.4.2. Commissioning ....................................................................................................... 13

2.4.3. Operation................................................................................................................ 13

2.4.4. Special work in the context of using the machine.................................................. 14

2.5. Note relating to special types of danger ......................................................................... 14

2.5.1. Risks to the operator from the machine ................................................................. 14

2.5.2. Dust ........................................................................................................................ 15

2.5.3. Noise ...................................................................................................................... 15

2.5.4. Exhaust fumes ........................................................................................................ 15

2.5.5. Hydraulic System.................................................................................................... 15

2.6. Transport ......................................................................................................................... 15

2.7. Packaging and storage .................................................................................................... 16

2.8. Environmental protection ................................................................................................ 16

2.9. Disposal .......................................................................................................................... 16

3. Machine Description ..................................................................................................... 17

3.1. Denomination of machine parts ...................................................................................... 17

3.2. Specifications ................................................................................................................. 18

3.3. Sound power level .......................................................................................................... 19

3.4. Whole body vibration ...................................................................................................... 19

4. Commissioning ............................................................................................................... 20

4.1. Connections and Consumables ....................................................................................... 20

4.2. Required Accessories ...................................................................................................... 20

5. Installation on the Floor Saw ......................................................................................... 21

5.1. Water supply ................................................................................................................... 21

5.2. Mechanical connection ................................................................................................... 22

5.3. Speed sensor .................................................................................................................. 24

5.4. Hydraulic connection ....................................................................................................... 27

6. Schneidwelle Ein- und Ausbau ..................................................................................... 28

6.1. Installing/replacing the diamond blades (tool) ................................................................ 32

7. Transport ........................................................................................................................ 34

7.1. Transport position ........................................................................................................... 34

8. Operation ........................................................................................................................ 35

8.1. Safety .............................................................................................................................. 35

8.2. Support wheel setup ....................................................................................................... 36

8.3. Setup grinding depth ....................................................................................................... 37

8.4. Grinding operation .......................................................................................................... 38

8.5. Relocating the machine................................................................................................... 38

8.6. Plane grinding height adjustment ................................................................................... 39

9. Maintenance .................................................................................................................. 40

9.1. Lubrication points ............................................................................................................ 41

9.2. Troubleshooting .............................................................................................................. 42

9.3. Maintenance Plan ........................................................................................................... 43

10. Warranty ....................................................................................................................... 44

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1.

PROPERTIES & ADVANTAGES

The Grooving Unit is used for grinding and texturing concrete and asphalt surfaces, e.g. to remove unevenness and

transitions or to make grooves to reduce aquaplaning in roadways and runways. Up to 210 diamond saw blades can

be mounted directly next to each other on the grinding shaft of the grooving unit over a maximum width of 600mm.

During the so-called grooving (groove grinding), spacers ensure the desired distance between the saw blades. When

the Grooving Unit is lowered, the rear axle of the floor cutter is detached from the floor, the wheels of the grooving

unit then act as a new rear axle. This extends the axle distance and the rear axle is at the optimum distance from the

grinding shaft.

The Grooving Unit is designed to work together with the fully hydraulic floor cutters.

• Mounting unit for grooving and Grooving in a robust and compact design

• The tool is lowered and lifted continuously via the slide box of the floor cutter

• Wide range of combination options thanks to customer-specific spacers across the entire working width

• Ready for connection to grinding sludge vacuum extraction unit

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2.

GENERAL SAFETY

2.1. Intended use policy

The manufacturer and supplier assume no liability for inappropriate use or usage other than the

intended use. No alterations may be made to the machine unless carried out by the manufacturer.

Changes resulting from extensions or conversions to the floor saw may only be executed with written

permission of the manufacturer.

The machine is designed and built to the state-of-the-art and the acknowledged safety regulations.

Nevertheless, there may be dangers to life and limb for the user or third parties, damages to the

machine or other property items.

The machine may only be used when it is error-free, in the intended manner, in a safety-conscious and

risk-aware manner and in accordance with the operating manual. In particular, faults which can affect

safety must be corrected immediately.

Intended use The LISSMAC Grooving Unit is a machine designed for Grooving/Texturing concrete or asphalt traffic

surfaces by wet grinding with a horizontal grinding shaft made of stacked diamond blades. The

Grooving Unit may only be attached to a LISSMAC floor saw of the UC series with a suitable grinding

slurry suction unit.

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.

Non-intended use Foreseeable misuse / non-intended use:

 Grinding without blade guard

 Grinding without water

 Grinding steeply sloped areas

 Grinding tight radii

 Grinding loose material

 Grinding wood, plastic or metal

(other than reinforcement in concrete)

 Structural modifications which alter the floor saw safety or design

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2.2. Organizational measures

This operating manual must be kept within easy reach for everybody 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.

Similar obligations may also arise in relation to e.g. handling hazardous substances, wearing personal

protective equipment, road traffic regulations.

The personnel contracted to carry out tasks involving the machine must have read and understood the

operating manual before starting work, in particular the section Safety Notices. This particularly

applies to personnel who only work on the machine occasionally, for example maintenance personnel.

Regularly check that the personnel is working in a safety and danger-conscious manner in accordance

with the instructions given in the operating manual.

Always use the required and mandatory, personal protection equipment.

Observe all safety and danger notices on the floor saw and keep them in a legible state.

Replace damaged safety and danger notes or those which have become illegible.

In the event of safety-relevant changes to the machine or in its operational behavior, shut the machine

down immediately with and label it accordingly. Report the fault to the responsible place/individual.

Do not implement any extensions or modifications to the cutter without written permission from the

manufacturer. The tool manufacturer’s instructions must be observed.

Only use tested original spare parts from the manufacturer.

Adhere to inspection periods as prescribed or indicated in the manual.

To carry out maintenance activities, it is essential to have an appropriately equipped workshop.

Machines with combustion engines must not be used indoors.

Before grinding, always obtain detailed information regarding hidden gas, electricity or

telecommunication lines in the grinding area, and take the appropriate cautionary measures.

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2.3. Choice of personnel and qualifications; 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, in writing by the

employer, to operate the floor saw.

Specify the responsibilities of the personnel for operation, set-up, maintenance and repair.

Ensure that only trained and expressly assigned personnel is working on the machine.

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

hearing protection that comply with the local safety regulations.

Direct any persons not working with the machine to leave the work area. If necessary, cordon off the

working area.

If the floor saw is in motion, the operator must ensure he does not endanger himself and other

persons. All obstructions at the place of work which hinder the work procedure or the use of the

machine must be removed.

Work on the machine’s electrical equipment 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 specified as the responsible party with respect to traffic regulations, and must

be authorized to refuse to execute third-party instructions that violate safety regulations.

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 notices regarding the operating phases

2.4.1. Transport and installation

The machine may only be transported when all parts have been tightened and individual parts cannot

fall off.

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2.4.2. Commissioning

Observe the grinding direction of the diamond blade when installing.

All cuts are performed as up-cuts.

When fitting the saw blade, protect your hands from sharp edges.

Clear all obstacles from the grinding area and provide good lighting.

Supply steady water for saw blade cooling.

Visual inspection of the entire machine for damage and defects.

Specifically check of the safety devices.

The permissible speed of the tool must always match or exceed the maximum nominal speed of the

grinding shaft.

Defective or broken tools must be replaced immediately.

2.4.3. Operation

Refrain from any unsafe working procedures.

Implement measures to ensure the machine is only used if it is safe and functional.

Check the machine for visible damage and defects prior to every shift! Notify the responsible

place/person immediately of any changes (including the operational behavior)!

In the event of malfunctions, shut down and secure the floor saw immediately! Have faults repaired

immediately.

Only use appropriate, tested tools.

Avoid any contact with the rotating tool. Maintain a safety distance of 1.5m from the grinding shaft.

Grinding shaft keeps coasting after power shutdown! Do not open the guards until the shaft is

stationary.

Do not cut without a blade guard.

The operator must be protected from rotating parts.

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2.4.4. Special work in the context of using the machine

Comply with the dates and activities for configuration, maintenance and inspection as prescribed in this

operating manual, including the details regarding replacement of parts/partial equipment. These

activities may be only be carried out by authorized expert personnel.

Perform lockout/tagout if the floor saw has been shut down for maintenance and repair work, to

prevent it being switched on again unexpectedly.

Before cleaning, all openings into which cleaning products must not ingress for safety and/or functional

reasons, must be covered and sealed. Motors, bearings and plug connectors are particularly at risk.

Remove covers/tape completely after finishing the cleaning work.

Always tighten loosened screw connections during maintenance and repair work.

If it is necessary to disassemble safety features for start-up, maintenance or repair, these devices must

be reassembled and checked immediately after finishing maintenance and repair work!

2.5. Note relating to special types of danger

2.5.1. Risks to the operator from the machine

The engine on the floor saw may only be operated for the intended use:

Floor saw blade drive

The outlet of the exhaust pipe must always point away from the operator.

Do not inhale exhaust gases.

The exhaust system becomes hot during operation. Avoid contact and wear protective equipment.

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2.5.2. Dust

When working in enclosed areas observe any existing national regulations.

For indoor grinding the use of an APF 10 (N-95) half mask is mandatory.

To prevent dust formation while grinding, the saw blade must be continuously sprayed with water.

Do not eat, drink or smoke in the work area.

2.5.3. Noise

See Section 3.3

2.5.4. Exhaust fumes

Machines with internal combustion engine must not be operated indoors.

2.5.5. Hydraulic System

Hydraulic hose lines must be replaced every 6 years, even if no safety-relevant defects are visible.

Never disconnect or connect hydraulic connections that are under pressure.

2.6. Transport

When moving with a crane, slings with sufficient lifting capacity must be used. Check slings for

damage before use.

Secure the load properly in compliance with national regulations.

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2.7. Packaging and storage

In order to ensure sufficient protection during dispatch and transport, the machine and its components

have been carefully packed. On receipt of the machine, it should be checked for damage. The device

packaging consists of recyclable materials. Please place these into the appropriate collection

containers, so that they can be recycled.

If there is any damage, the machine must not be operated. Damaged cables and plug connections also

pose a danger and may not be used.

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

dirt.

2.8. Environmental protection

Packing material, cleaning agents, used or residual operating materials, and unpacked wear parts

such as drive belts or engine oils must be sent for recycling in line with the applicable environmental

protection provisions for the place of use.

2.9. Disposal

When the device reaches the end of its service life, in particular if malfunctions occur, render the

worn-out device unusable.

Dispose of the device according to the national or local environmental protection legislation.

Electrical waste may not be disposed of with household waste. Take the disused device to a central

collection point.

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3.

MACHINE DESCRIPTION

3.1. Denomination of machine parts

Pos. 1 Support leg Pos. 10 Turnbuckle

Pos. 2 Adapter plates Pos. 11 Height adjustment suction back

Pos. 3 Protective cover Pos. 12 Cover hold-down device

Pos. 4 Height adjustment suction front Pos. 13 Suction frame

Pos. 5 Collector for suction Pos. 14 Spray bar water supply

Pos. 6 Connecting plate hydraulic return flow Pos. 15 Shaft cover

Pos. 7 Leakage oil plug-in coupling

Pos. 8 Connecting plate hydraulic flow

Pos. 9 Grinding depth adjustment

3

2

1

13

10

9

15

12

14

8

6

4

11

7

5

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3.2. Specifications

Minimum diamond blade diameter 230 mm / 9’’

Maximum diamond blade diameter 300 mm / 12’’

Maximum grinding depth

with 230 mm blades

with 300 mm blades

25 mm / 1’’

60 mm / 2.4’’

Maximum number of saw blades ca. 210

Diameter of the milling shaft 60 mm / 2.4’’

Maximum processing width 600 mm / 23.6’’

Number of tie rods 3

Displacement of the shaft drive motor 45 cm3 / 2.75 in³

Speed of the milling shaft max. 3600 min-1 / RPM

Length/width/height in mm 850 - 1480 - 800 / 33.5’’- 58’’- 31-5’’

Weight (empty shaft) 390 kg / 860 lbs

850

1480

800

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3.3. Sound power level

WARNING

Danger of hearing damage

As from a sound power level of 85 dB (A), wearing ear protectors is mandatory.

 Where your personal hearing protection.

The values for emission sound pressure at the workplace LpA and guaranteed sound power level correspond

to that of the floor saw with a standard setup.

3.4. Whole body vibration

The total vibration value aHV corresponds to that of the floor cutter with standard equipment.

The effect can be inversely proportional to the weight of the operator.

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4.

COMMISSIONING

4.1. Connections and Consumables

Hydraulic fluid The machine uses the hydraulic oil circuit of the connected floor saw.

Grease points Only use quality grease on the grease nipple. The grease used on the floor saw bears the designation

"Energrease LS2 BP".

(Lithium saponified multi-purpose grease of NLGI Class 2 according to DIN 51818 / NLGI GC - LB Grade 2)

Water supply The water pressure in the supply line must not exceed 5 bar.

If necessary, connect a pressure reducer upstream and use clean water only.

This information refers to the usual operating and environmental conditions.

Other specifications may be required for use under extreme climatic conditions.

4.2. Required Accessories

Diamond blades Saw blades are available in 230, 250 and 300 mm.

For both asphalt and concrete.

Spacer Discs You need at least one stainless steel spacer disc with 180 mm in diameter between two diamond saw blades.

Standard spacer discs are available in the following thicknesses.

Thickness Article Number

0.8 mm 755502

1.0 mm 755503

1.5 mm 755504

2.0 mm 755505

2.5 mm 755506

5.0 mm 755507

10 mm 755508

30 mm 755509

(Customized sizes are available on request).

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Lissmac Grooving Anbausatz Owner's manual

Lissmac Grooving Anbausatz Owner's manual

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