Lissmac UNICUT DT0 Owner's manual

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OPERATING MANUAL

MICRO-TRENCHING FLOOR SAW

Nextec Trencher DT 60

LISSMAC Maschinenbau GmbH

Lanzstrasse 4

88410 Bad Wurzach, Germany

Phone +49 (0) 7564 / 307-0

Fax +49 (0) 7564 / 307-500

lissmac@lissmac.com

www.lissmac.com

EN

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Legal notice This operating manual is valid for:

• Nextec Trencher DT60

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

Translation of original operating manual

Issue date: 01-2021

Keep manual for future reference!

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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Warning and safety notes used:

Read the operating manual

Wear safety goggles

Wear hearing protection

Wear protective gloves

Wear protective helmet

Wear dust mask

Wear work clothes and wash regularly.

Sound power level of the machine

/ Attachment point for crane transports

Remove the ignition key before working on the unit

Cutting hazard at the rotating tool

Wait for all parts to stop

Do not relocate the machine with rotating tool

Extremely flammable fuel vapours

Warning of crushing hazard.

Danger due to ejected parts

Warning of suspended loads

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Warning of falling parts.

Warning of hot surfaces.

Warning of toxic fumes.

Warning of potential injuries due to high pressure leaks.

Warning of electric shock due to damaged power lines.

Warning of batteries.

Explosion hazard

Do not use high pressure cleaners

Use by unauthorised persons not permitted

Do not enter the area

Smoking prohibition

Lashing point for vehicle transport

Instruction for damage prevention.

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OPERATING MANUAL

Preface This operating manual is designed to make it easy to familiarise 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

For completeness regarding further documentation, LISSMAC does not assume responsibility or liability

regarding their completeness.

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. Organisational measures ................................................................................................ 13

2.3. Choice of personnel and - qualification; fundamental obligations .................................. 14

2.4. Safety notes regarding the operating phases ................................................................. 14

2.4.1. Transport, assembly and installation ..................................................................... 14

2.4.2. Start-up .................................................................................................................. 15

2.4.3. Operation ............................................................................................................... 15

2.4.4. Relocating the floor saw ........................................................................................ 16

2.4.5. Special work while using the machine .................................................................. 16

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

2.5.1. Dangers for the operator from the machine ........................................................... 16

2.5.2. Electrical energy .................................................................................................... 17

2.5.3. Dust........................................................................................................................ 17

2.5.4. Noise ...................................................................................................................... 17

2.5.5. Exhaust fumes ........................................................................................................ 17

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

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

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

2.9. Disposal .......................................................................................................................... 18

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

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

3.2. Connections/interfaces ................................................................................................... 20

3.3. Technical specifications.................................................................................................. 21

3.4. Sound power level .......................................................................................................... 22

3.5. Exhaust fumes ................................................................................................................ 22

3.6. Hand-Arm vibration ......................................................................................................... 23

4. Commisioning ................................................................................................................. 24

4.1. Connections and media .................................................................................................. 24

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

4.3. Water supply .................................................................................................................. 25

4.4. Refuelling ........................................................................................................................ 26

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

5. Control desk ................................................................................................................... 28

5.1.1. Joystick .................................................................................................................. 29

5.2. HMI control unit .............................................................................................................. 30

5.2.1. Dashboard .............................................................................................................. 31

5.2.2. Pre-selection page 1 .............................................................................................. 32

5.2.3. Pre-selection page 2 .............................................................................................. 33

5.2.4. Fault memory ......................................................................................................... 34

5.2.5. Overview ................................................................................................................ 35

5.2.6. Display settings ..................................................................................................... 36

5.2.7. Service menu ......................................................................................................... 37

5.2.8. Software adjustment ............................................................................................. 37

6. Transport ........................................................................................................................ 38

6.1. Transport position ........................................................................................................... 38

6.2. Procedure in cutting or rapid traverse mode ................................................................... 39

6.3. Relocating using a crane................................................................................................. 41

6.4. Securing the machine for transport ................................................................................ 42

7. Operation ........................................................................................................................ 43

7.1. Safety ............................................................................................................................. 43

7.2. Preparing the floor saw .................................................................................................. 45

7.2.1. Setting up the saw blade ....................................................................................... 45

7.2.2. Setting up the Laying unit ...................................................................................... 46

7.3. Relocating or positioning the floor saw .......................................................................... 48

7.4. Cutting with the floor saw .............................................................................................. 48

7.5. Initiating the cutting process .......................................................................................... 49

7.6. Lower the Laying unit in the cutting kerf ........................................................................ 49

7.7. Comfort Mode ................................................................................................................. 50

7.8. Setting toe in .................................................................................................................. 51

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7.9. Safe machine shutdown ................................................................................................. 52

7.10. Other adjustment options ............................................................................................. 52

8. Servicing......................................................................................................................... 53

8.1. Maintenance intervals .................................................................................................... 53

8.2. Air filter added ................................................................................................................ 54

8.3. Cleaning the water pump set .......................................................................................... 55

8.4. Cleaning the distribution unit ......................................................................................... 55

8.5. Fuses ............................................................................................................................... 56

8.6. Lube points ..................................................................................................................... 58

8.7. Troubleshooting .............................................................................................................. 59

8.8. Support and training ....................................................................................................... 60

8.9. Torque values of screw connections ............................................................................... 60

8.10. Regeneration of the SCR system "standstill" ................................................................ 61

8.11. SCR monitoring ............................................................................................................. 63

8.12. Refuelling AdBlue/DEF.................................................................................................. 64

8.13. Torques of screw connections ...................................................................................... 66

8.14. Maintenance schedule.................................................................................................. 67

9. Tools ............................................................................................................................... 68

10. Warranty ....................................................................................................................... 69

11. Circuit diagram ............................................................................................................. 71

12. Hydraulic diagram (schematic) ................................................................................... 88

13. Error codes ................................................................................................................... 90

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1.

FEATURES & BENEFITS

Many years of experience have led to the development of Nextec Trencher DT 60 especially for

professional users in cooperation with them. This floor saw is a single device that allows carrying out

a variety of jobs.

 Easy operation - thanks to the multifunctional joystick

 Optimised hydraulic circuit through electro-hydraulic steering, thus higher power transmission

to the saw blade

 Traction drive and saw blade speed are electro-hydraulically adjustable - optimum cutting

speed of the saw blade

 Optimum weight distribution - low centre of gravity

 Large sized fuel tank reduces downtime

 Large, non-marking drive wheels

 4-wheel drive for high traction

 The blade guard is hydraulically height-adjustable, independent of the saw motor

 All settings can be made on the central display and all engine values can be read on the display

 Easy access for common maintenance (air filters, oil and fuel filters)

 The Nextec Trencher DT60 complies with the emission regulations of US EPA Tier 4/EU

category IV

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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 recognised 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 grinder and is designed exclusively for cutting

joints in concrete or asphalt with the help of water. The cutting includes saw blades and may only be

used for cutting on the ground. The floor saw may only be operated by one person. The operator must

remain in the driver's seat of the floor saw as long as the machine is running. Any use other than this

will be deemed unintended.

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

and maintenance manual.

Unintended use Foreseeable misapplications / unintended use:

 Cutting without blade guard

 Cutting without water

 Cutting on steep slopes

 The cutting of narrow radii

 Cutting wood, plastics or metal

(except reinforced concrete)

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

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2.2. Organisational measures

This operating manual must be kept within easy reach for everyone at the place of use.

Keep this manual for future reference.

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.

If safety-related changes in the operational behaviour should occur, 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 indoors or in confined spaces.

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 authorised 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.

Transport may only take place, if all parts at the machine are tightened and dropping of individual

parts is impossible.

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2.4.2. Start-up

Check the direction of rotation when fitting the saw blade. The cutting process must always be counter

rotational (up-cut); otherwise, the material will not be transported out of the kerf.

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. Separate check of the protective

devices.

Supply water for saw blade cooling.

Smoking is prohibited when refuelling the internal combustion engine.

Particular care should be taken when refilling the fuel tank. 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

Refrain from any work practice that might compromise safety.

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

behaviour). 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 eliminated

immediately. Electrical installation work may only be accomplished 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.

In case of fire, persons must follow the operator's fire protection instructions.

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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.

There is a risk of injury from a rotating saw blade.

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 authorised 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 being accidentally switched on again.

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 tighten screw connections rendered loose during maintenance and repair work.

If the disassembly of safety devices is necessary with the start-up, maintenance and repair, the

assembly and check of the safety devices must take place immediately after conclusion of maintenance

and repair work.

No rotating tool, whose maximum speed is lower than the rated speed of the machine, must be used.

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.

There is a risk of injury from a rotating saw blade.

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

Drive of the floor saw and the saw blade are put into operation.

Depending on the seating position, the exhaust system may be unfavourable for the operator.

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 protective equipment.

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2.5.2. Electrical energy

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.

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

marked to ensure that it will not be started by others.

2.5.3. Dust

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

To prevent dust formation during cutting, the saw blade must be continuously sprayed with water and

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

2.5.4. Noise

See section 3.4

2.5.5. Exhaust fumes

Machines with internal combustion engine must not be operated in closed rooms.

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 an expert instructor for the hoisting work.

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 load properly in compliance with the regulations. Use suitable lashing points.

The engine of the floor saw must be switched off even for a minor change of location. The blade must

not rotate when restarted directly.

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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 packed carefully. The machine should be checked for damage upon receipt. The machine's

packaging consists of recyclable materials. Please sort them into different materials and place them in

the appropriate containers so that they can be recycled.

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

and must not be used. In this case notify the manufacturer immediately.

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 environmental protection regulations

in force at the place of use.

2.9. 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 environmental regulations valid in your country. Electrical

waste may not be disposed of together with household waste. Deposit the end-of-life device at a

central collection point.

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3.

DEVICE DESCRIPTION

3.1. Designation of machine parts

Item 1 Driver's seat Item 12 Ejection channel

Item 2 Joystick Item 13 Access to engine oil refill nozzle

Item 3 Display Item 14 Diesel tank

Item 4 Water tank Item 15 Water pump

Item 5 Steering rod Item 16 AdBlue®/DEF tank

Item 6 Balancing weights Item 17 Blade spray distributor

Item 7 Emergency stop Item 18 Cutting shaft flange

Item 8 Ignition key Item 19 Vibrator at the Laying unit

Item 9 Vibrator at the ejector Item 20 Laying unit vane

Item 10 Filter at the ejector Item 21 Cable insertion aid

Item 11 Blade guard

20

1

2

3

4

13

12

1

16

11

19

21

5

6

8

7

9 10

18

14

15

17

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3.2. Connections/interfaces

Power

Item 1 Socket water pump 12V (15A) switchable

Item 2 Socket 1 12V (10A) switchable

Item 3 Socket 2 12V (10A) switchable

Item 4 Socket 3 12V (10A) switchable

Item 5 Socket 4 12V (10A) switchable

Item 6 Socket 5 12V (10A) constant current

Engine

Item 7 Ambient air temperature sensor

Diagnosis

Item 8 Connecting plug diagnosis (only for service)

Controller

Item 9 Control desk connection

Hydraulics

Item 10 Hydraulics P (pressure)

Item 11 Hydraulics T (tank)

Item 12 Hydraulics leakage oil

Water

Item 13 Water connection (max. 5 bar)

Light switch

Item 14 LED lighting

2 3 5 6

13

11 10 9 12

4

8

1

7

14

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Lissmac UNICUT DT0 Owner's manual

Lissmac UNICUT DT0 Owner's manual

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