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OPERATING MANUAL
FLOOR SAW
MULTICUT 400 D
MULTICUT 400 P
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
EN
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Imprint The operating manual is valid for:
LISSMAC floor saw
MULTICUT 400 D
MULTICUT 400 P
Headquarters:
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: 01-2023
Keep this Operating Manual for future reference!
Disclosure and copying Transfer and reproduction of this operating manual in any form, as well as the use of its contents,
are forbidden without written consent.
All contraventions oblige the payment of damages. All rights reserved for registration of a patent,
utility model or design.
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BASIC SAFETY INSTRUCTIONS
Warning information and symbols in this manual
Type and source of danger
Consequence of non-compliance.
Measures to prevent the hazard
The signal word after the hazard symbol indicates the level of danger:
DANGER
This indicates an extremely dangerous situation. If the situation is not avoided, it will likely
result in fatal injuries. The hazard symbol may give details of the danger.
WARNING
This indicates a potentially dangerous situation. If the situation is not avoided, it may result in
fatal or serious injuries. The hazard symbol may give details of the danger.
CAUTION
This indicates a hazardous situation. If the situation is not avoided, it may result in moderate
or minor injuries. The hazard symbol may give details of the danger.
NOTICE
This signal word indicates a situation that involves hazards for objects. If the situation is not
avoided, it may result in property damage. The signal word is used without a hazard symbol.
Important information is marked with an "i".
Requirement for the operator to take action:
1. Prescribed order of handling steps.
• Handling instructions to the operator
The warning notes contained are not exhaustive.
Lissmac cannot predict every possible hazard.
The suitable safety rules and precautions are to be followed as with any other machine, in
regards to the working method and operation.
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The following warning and safety instructions are used:
Read the operating manual
Wear hearing protection
Wear eye protection
Wear gloves
Wear protective helmet
Wear dust mask
Wear suitable work clothing
Attachment points for crane transport
Remove the ignition key before working on the device
Cutting hazard at the rotating tool
Do not relocate the machine with rotating tool
Extremely flammable fuel vapours
Risk of crushing due to unintentional movement
Danger due to ejected parts
Danger due to suspended loads
Hot surfaces. Contact can cause burns
Danger of suffocation due to toxic gases
Danger due to battery acid
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Explosion hazard
Danger of drawing in due to open belt drive
Risk of cutting injuries and amputation due to rotating cutting tools
Do not use high pressure cleaners
No unauthorised persons allowed
Smoking prohibition
Harmful substances: Fine silica dust
No maintenance activities allowed when the engine is running
Instruction for damage prevention.
Lashing point for vehicle transport
Sound-power level of the machine
Visual inspection
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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 in a safe, proper
and economical manner. 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 on the basis of existing national
regulations on accident prevention and environmental protection.
The operating manual must be available at the location of the machine at all times.
The operating instructions must be read by every person who works with or on the machine, and the
instructions given must be followed, e.g.:
operation, set-up, troubleshooting in the work process, removal of production waste, care,
disposal of operating and auxiliary materials;
maintenance, inspection, 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.
Other relevant documents Further documentation of the corresponding manufacturer of the individual components of the machine
is available to complete this Operating Manual:
Internal combustion engine operating manual
LISSMAC does not accept any responsibility or liability for the completeness of the additional
documentation.
Changes and reservations We have taken every effort to ensure that this operating manual is correct and up to date. In order to
maintain our technological lead, it may be necessary to make modifications to the product and to its
operation without notice. We accept no liability for faults, downtime and resulting damage.
Target group This Operating Manual is aimed at trained, skilled personnel in the fields of building mechanics,
concrete cutting technology, road construction, building construction and civil engineering.
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Notes:
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Table of contents
1. Features & benefits ........................................................................................................ 10
2. General safety instructions ............................................................................................ 11
2.1. Purpose; intended use .....................................................................................................11
2.2. Organisational measures .................................................................................................12
2.3. Choice of personnel and personnel qualifications; fundamental obligations ..................13
2.4. Safety notes regarding the operating phases ..................................................................13
2.5. Note relating to special types of danger .........................................................................15
2.6. Transport .........................................................................................................................16
2.7. Packing and Storage ........................................................................................................17
2.8. Environmental protection ................................................................................................17
2.9. Disposal ...........................................................................................................................17
3. Device Description ......................................................................................................... 18
3.1. Names of the machine parts ...........................................................................................18
3.2. Back and interior .............................................................................................................19
3.5. Technical data .................................................................................................................22
3.6. Sound power level ...........................................................................................................23
3.7. Hand-arm vibration ..........................................................................................................23
3.8. Exhaust fumes .................................................................................................................24
4. Transport......................................................................................................................... 25
4.1. Transport position ...........................................................................................................25
4.2. Relocating using a crane .................................................................................................26
4.3. Securing the machine for transport .................................................................................27
5. Commissioning ............................................................................................................... 28
5.1. Refuelling ........................................................................................................................28
5.2. Water separator MC400D ...............................................................................................29
5.3. Tools (saw blade) ............................................................................................................29
5.4. Saw blade installation/change (tool) ...............................................................................30
5.5. Checking the drive belt tension .......................................................................................32
5.6. Retightening the V-belts ..................................................................................................33
5.7. Changing the V-belts .......................................................................................................34
6. Operation ........................................................................................................................ 36
6.1. Safety ..............................................................................................................................36
6.2. Start preparations ...........................................................................................................38
6.3. Setting the lowering speed .............................................................................................38
6.4. Setting the operating position .........................................................................................38
6.5. Starting and stopping the engine ....................................................................................39
6.7. Setting toe in ...................................................................................................................40
6.8. Cutting with the floor saw ...............................................................................................41
6.9. Repositioning the floor saw.............................................................................................43
6.10. Swtiching into freewheel ..............................................................................................43
6.11. Switching off the floor saw ...........................................................................................44
6.12. Changing from right to left cut ......................................................................................45
6.13. Widening the blade holder ............................................................................................46
6.18. Cutting with the blade guard opened ............................................................................50
7. Maintenance .................................................................................................................. 51
7.1. Operating materials .........................................................................................................51
7.2. Maintenance MC 400 D ..................................................................................................53
7.3. Maintenance MC 400 P ...................................................................................................54
7.4. Checking the oil level ......................................................................................................55
7.5. Bleeding the hydrostatic drive .........................................................................................56
7.6. Draining the engine oil ....................................................................................................57
7.7. Lubrication points ............................................................................................................58
7.8. Storage conditions ..........................................................................................................59
7.9. Troubleshooting ...............................................................................................................59
7.10. Maintenance plan..........................................................................................................60
8. Tools ................................................................................................................................ 61
9. Warranty ......................................................................................................................... 62
10. Circuit diagram ............................................................................................................. 64
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1.
FEATURES & BENEFITS
The requirements arising from practice were taken into account in the development of these versatile
power packs. The diesel floor saws, proven and tested by professionals, are convincing thanks to their
excellent price-performance ratio, robust technology and simple operation.
Optimum power transmission thanks to high-performance V-belts
Torsion-resistant frame sheet construction
Compact design and balanced chassis allow easy manoeuvring on site
The extremely low centre of gravity ensures an exact saw cut
Very good straight cut due to adjustable rear axle
The lifting and lowering of the saw blade can be controlled electro-hydraulically
Height-adjustable handles
For overcuts, the saw blade hood can be folded up at the front as standard
Very fast conversion from left to right cut
Easy access for common maintenance (air filters, battery, oil and fuel filters)
Parking brake, operating hours counter and freewheel as standard
MC 400 D
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2.
GENERAL SAFETY INSTRUCTIONS
2.1. Purpose; intended use
The manufacturer and supplier do not accept any liability for incorrect or non-intended use. Any
modification to the machine not carried out by the manufacturer is forbidden. Modifications due to
extensions or conversions of the floor saw require the manufacturer’s written consent.
The machine is built according to the state of the art and the recognised safety-related rules. Its use
can, nevertheless, result in hazards for life and limb of the user or third persons, as well as damage to
the machine and other material assets.
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,
always resolve faults which may impair safety, or have them resolved, immediately.
Intended Use The LISSMAC floor saw is a type of floor cutting grinder and is designed exclusively for wet cutting
joints in concrete or asphalt. Cutting requires a tool in the form of a diamond saw blade. The joint
cutter may only be operated by one person. The operator must remain behind the handles as long as
the machine is running.
Any other use is considered contrary to the intended use.
Proper use also includes compliance with the operating instructions and compliance with the
inspection and maintenance instructions.
Improper Use Foreseeable misuses / non-intended use:
Cutting without blade guard
Cutting without water
Cutting loose material
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.
Supplements to the operating manual include general statutory and other binding regulations for
preventing accidents and protecting the environment and must be obeyed.
Such regulations may also deal with, for example, the handling of hazardous substances, the wearing
of personal protective equipment and with road traffic regulations.
The personnel assigned to work on the machine must have read and understood the Operating
Manual, and especially the chapter on Safety instructions, before beginning the work. This particularly
applies to personnel who only work on the machine occasionally, for example set-up and maintenance
personnel.
Regularly check the safety- and hazard-aware work of the personnel in compliance with the Operating
Manual.
Always use the required and prescribed personal protective equipment.
Observe all safety and hazard warnings on the floor saw, and maintain them in a legible condition.
Replace damaged or illegible safety and hazard warnings.
If there are any changes to the machine or operating behaviour which may affect safety, stop the
machine immediately and put up warning signs accordingly. Report the fault to the responsible
office/person.
Do not make any modifications through extensions or conversions without the manufacturer’s written
consent. The tool manufacturer’s instructions must be adhered to.
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 personnel qualifications; 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.
Establish the responsibilities of the personnel for operation, set-up, service and repair.
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. Block access to the work 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 components of the machine may only be carried out by a certified electrician or
by persons who are being instructed in such work under the direction and supervision of a certified
electrician in accordance with 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 engine switched off.
Use a crane to load and unload the floor saw, taking the maximum operating weight into account.
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. Commissioning
When fitting the saw blade, protect your hands from sharp edges.
Make sure the substrate that is used for cutting meets the load-bearing capacity. All obstacles must be
removed from the cutting area and good lighting must be provided.
Visual check of the entire floor saw for any damage and defects. 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 all methods of working which could pose a risk to 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 the machine down and secure it against being switched on again.
If the floor saw fails to work properly, shut it down immediately and secure it. Have faults eliminated
immediately. Electrical work must only be carried out by qualified electricians.
Only use suitable and tested 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 protective hood of the saw blade is prohibited.
The operator must be protected from rotating parts.
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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.
A rotating saw blade poses a high risk of injury.
2.4.5. Special work while using the machine
Comply with the set-up, maintenance and inspection activities and intervals stipulated in this Operating
Manual, including information on the exchange of parts/furnishings. These activities must only be
carried out by authorised professionals.
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 that cleaning products should not enter for safety and/or
functional reasons. Electric engines, switches, and connectors are particularly at risk. Remove the
covers/adhesive tape completely after finishing the cleaning work.
Always fasten screw connections securely after maintenance and repair work.
If safety devices must be dismounted for preparation, repair or maintenance of the machine, they must
be mounted and inspected immediately after the duties have been terminated.
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.
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.
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 power
Only use original fuses with the prescribed amperage. The floor saw must be switched off
immediately in the event of faults. Electrical work may only be carried out by certified and qualified
technical personnel.
Regularly inspect and test the electrical equipment of the machinery. Defects such as loose
connections or damaged cables must be remedied immediately. 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 where applicable.
To prevent dust formation during cutting, the saw blade must be continuously sprayed with water and
cooled. Do not eat, drink or smoke in the work area.
2.5.4. Noise
See Section 3.5
2.5.5. Exhaust fumes
Machines with internal combustion engine must not be operated in closed rooms.
2.6. Transport
Lifting tackle with sufficient carrying capacity must be used when moving with a crane. Examine the
lifting tackle for damage before it is used.
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 capacity.
Secure the load properly in compliance with the regulations. Use suitable attachment points.
The saw engine must also be switched off or disconnected if there is a slight change of location.
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2.7. Packing and Storage
In order to ensure sufficient protection during dispatch and transport, the machine and its components
were packed carefully. The machine should be checked for damage upon receipt. The packing of the
device consists of recyclable materials. Place them into the containers provided for recycling so that
they can be recycled.
The machine may not be operated in case of damage. 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 from moisture and
dirt.
2.8. Environmental protection
Packaging material, cleaning agents, used or remaining operating supplies, and unwrapped wear
parts, such as drive belts or engine oils, must be recycled in accordance with local environmental
regulations.
2.9. Disposal
Render the worn out devices unusable once the period of use has expired, and especially when there
are malfunctions.
Dispose of the machine according to the environmental regulations valid in your country. Electrical
waste must not be dumped in general waste. Take the machine to a central collection point.
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3.
DEVICE DESCRIPTION
3.1. Names of the machine parts
1.
Handlebars
9.
Drive axle (hydrostat)
2.
Control panel
10.
Water connection with ball valve
3.
Diesel tank
4.
Air filter
5.
Hitch point for the crane, manual transmission
6.
Engine (diesel/petrol)
7.
Steering rod
8.
Blade guard (required accessory)
2
3 4
8
1
5
7
6
9
10
11
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3.2. Back and interior
To open the back wall
Unlock the back wall at the top with a square key and open out downwards.
1.
Pump and reservoir for
hydraulic unit for
saw blade lifting (HV68)
4. Hydrostat-gear oil reservoir (20W50)
2.
Drive/freewheel selector lever
5. Battery
3.
Adjusting screw
The correct hydraulic oil level can only be read when the machine is completely lowered.
4
5
3
2
1
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3.3. Control panel MC 400 D
NOTE
Operation of the machine
Before you start the floor saw, you must familiarise yourself with the operation first.
The personnel assigned with activities at the machine must have read the operating manual
before starting work, and here particularly the chapter safety notes.
Pos. 1
Fuel tank Pos. 11 Emergency stop
Pos. 2
Power connection DC 12V (max 10A) Pos. 12 Operating hours counter
Pos. 3
Engine coolant filler neck Pos. 13 Parking brake
Pos. 4
Fuse compartment Pos. 14 Warning light oil pressure
Pos. 5
Cutting depth indicator Pos. 15 Throttle for lowering speed
Pos. 6
Combi control lever feed and lift shear Pos. 16 Warning light alternator
Pos. 7
On-board tool kit Pos. 17 Water temperature warning light
Pos. 8
Extractor tool Pos. 18 Clamping block for dipstick cable
Pos. 9
Engine speed adjuster Pos. 19 Diesel fuel cap
Pos. 10
Ignition
Emergency stop mushroom button is an emergency stop device and must not be used as an off switch.
Use the ignition key to switch off the machine.
1 5
8
7
6
9
14
18
10
12
4 2 3
11 13
17
16
15
19
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