Lissmac UNICUT 500 Owner's manual

1

CONSTRUCTION TECHNOLOGY

OPERATING MANUAL

FLOOR CUTTER

UNICUT 500

LISSMAC Maschinenbau GmbH

Lanzstrasse 4

D-88410 Bad Wurzach

Telephone +49 (0) 7564 / 307-0

Fax +49 (0) 7564 / 307-500

[email protected]

www.lissmac.com

2

Imprint

Operating manual for

LISSMAC Floor Cutter UNICUT 500

Stand: 04-2013

Translation of the original operating manual

Company headquarters:

LISSMAC Maschinenbau GmbH

Lanzstraße 4

D - 88410 Bad Wurzach

Tel: +49 (0) 75 64/3 07-0

Fax: + 49 (0) 75 64/3 07-5 00

E-Mail: [email protected]

Web: www.lissmac.com

The dissemination or duplication of this operating manual in any form, or the reuse of contents is

forbidden unless permitted in writing. Non-compliance is subject to compensation for damages. All

rights reserved for the purpose of patent, utility model, or design patent registration.

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Preface to the operating manual

This operating manual should make it easier to get to know the machine and make use of its intended

applications.

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

and economically. Your close attention helps avoid risk, repair costs and downtime, and increase the

reliability and lifetime of the machine.

The operating manual is to be supplemented by directives for accident prevention and environmental

protection, according to applicable national requirements.

The operating manual is to be kept permanently available at the machine location.

The operating manual must be read and used by each person assigned to work with the machine,

e.g.:

 Operating, including tooling, troubleshooting during operating, correction of production rejects,

service, disposal of operating and auxiliary materials

 Maintenance (service, inspection, repair) and/or

 Transport

Along with the operating manual and the valid legal regulations for accident prevention in the country

of use and the place of use, also recognised technical regulations for safety and proper work are to be

observed.

Table of Contents

1. Basic safety instructions

2. Machine description

3. Commissioning

4. Transport

5. Operation

6. Maintenance

7. Accessories

8. Service work

9. Tools

10. Warranty

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1. Basic safety instructions

1.1 Warning notices and symbols in this operating manual

Danger! Indicates that failure to comply could lead to severe injury or

even death.

Caution! Indicates that failure to comply could sometimes lead to

injuries.

Note Indicates that failure to comply leads to damage to the machine

or other property.

Symbols on the machine:

Observe the operating manual

Wear hearing protection

Noise power level

Noise level of the machine

Risk of shearing from moving

parts

Rotating sawblade

Running direction of sawblade

5

1.2 Basics of intended use

1.2.1 The machine is constructed according to the state of the art and

recognised technical safety rules. However, danger to life and limb of the

user or third parties, and/or damage to the machine or other property

may still arise from its use.

1.2.2 Only use the machine in technically faultless condition and for intended

use, aware of safety and danger complying with the operating manual!

You should particularly handle malfunctions which can compromise

safety immediately, or have them addressed by experts!

1.2.3 The floor cutter is intended exclusively for cutting joints in concrete or

asphalt using the wet cutting method. Cutting of wood, plastic or metal

(except for reinforcement in concrete) is not allowed!

Any other use or use above and beyond is not considered intended use.

The manufacturer/supplier assumes no liability for damages caused by

failure to comply with the intended use.

Non-intended use particularly includes working without cooling water.

Dry cutting is prohibited because the dust endangers the health of the

operator and damages the motor.

Intended use also includes compliance with the operating manual and

observance of inspection and maintenance requirements.

1.3 Organisational measures

1.3.1 The operating manual is to be kept permanently at the machine location

and easily accessible!

1.3.2 Follow and instruct others in all generally valid legal and otherwise

binding regulations for accident prevention and environmental protection

in addition to the operating manual!

1.3.3 Personnel assigned to activities on the machine must have read the

operating manual, particularly the Safety Instructions chapter, before

starting work. In the middle of work it is too late. This applies notably to

personnel who only work occasionally on the machine, e.g. for

changeovers and service.

1.3.4 At least occasionally, perform checks for safe and hazard awareness

work by operators while following the operating manual!

1.3.5 Use personal protection equipment if necessary or required by

regulations!

1.3.6 Observe all safety and danger instructions on the machine!

1.3.7 Keep all safety instructions and danger warnings on/in the machine

complete and in legible condition!

1.3.8 At the presence of safety-related changes to the machine or its running

behaviour, stop the machine immediately and report the problem to the

responsible post/person!

1.3.9 No changes, removal or addition of parts to the machine without the

approval of the supplier!

1.3.10 Only use original replacement parts from the manufacturer!

1.3.11 Observe required or prescribed deadlines given in the operating manual

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7

for inspections!

1.3.12 Workshop equipment suitable for the work is absolutely necessary for

performing maintenance actions.

1.4 Personnel choice and personnel qualification; basic responsibilities

1.4.1 Work on the machine must only be performed by reliable personnel.

Observe the legal minimum age!

1.4.2 Only use trained or orientated personnel. Establish clear responsibilities

of the personnel for operating, changeover, servicing, and repairing the

machine!

1.4.3 Make sure that only authorised personnel work on the machine!

1.4.4 Establish the responsibility of the machine operator, also in respect to

traffic regulations, and enable him to refuse to follow instructions by third

parties that are contrary to safety!

1.4.5 Any personnel training, learning, being instructed, or currently involved in

general education may only work with the machine under the continual

supervision of an experienced person!

1.4.6 Work on the electrical equipment of the machine may only be carried out

by electricians or trained personnel under the management and

supervision of an electrician, and in accordance with the rules of

electronics.

1.5 Safety instructions for certain operation phases

1.5.1 Normal operation

1.5.1.1 Refrain from working in any manner that is questionable in regard to

safety!

1.5.1.2 Take measures to ensure that the machine is operated only in a safe,

functional condition!

1.5.1.3 At least once per shift check the machine for externally recognisable

damage and deficiencies! Any changes which occur (including operating

behaviour) must be reported immediately to the responsible post/person!

If necessary, immediately stop the machine and secure it!

1.5.1.4 Immediately stop and secure the machine in case of malfunctions!

Immediately correct malfunctions!

1.5.1.5 Before beginning work become familiar with the operating location and

working environment. The working environment includes, for example,

obstacles in the traffic area, bearing capacity of the floor, required

security of the construction site to the public traffic area and possibilities

for help in case of accidents.

1.5.2 Special work while using the machine and maintenance work as well as troubleshooting during

operation; disposal

1.5.2.1 Follow all setup, maintenance, and inspection activities and schedules

prescribed by the operating manual, including all information about the

replacement of parts / assemblies!

These activities may only be carried out by experts.

1.5.2.2 Inform operating personnel before beginning special and maintenance

work! Name a supervisor!

1.5.2.3 If the machine is completely turned off during maintenance and repair

work, it must be secured against unexpected application of power.

1.5.2.4 Before cleaning the machine with water or steam jet (high-pressure

cleaner) or other cleaning agents, cover/glue all openings in which no

water/steam/cleaning agent should penetrate due to safety and/or

functional reasons. Electric motor and switches are especially at risk.

1.5.2.5 After cleaning, remove the covers/tape completely!

1.5.2.6 During service and repair work, always tighten loose bolt joints!

1.5.2.7 If dismantling is required for fitting, servicing and repair, the safety fittings

must be remounted and checked immediately following the service and

repair work!

1.5.2.8 Please ensure the safe, environmentally friendly disposal of operating

and auxiliary materials and replacement parts!

1.6 Safety instructions for special types of dangers

1.6.1 Electric power

1.6.1.1 Use only original fuses with the specified current rating! In case of

problems with the electrical power supply, turn the machine off

immediately!

1.6.1.2 Work on the electrical operating equipment of the machine may only be

carried out by electricians or trained personnel under the management

and supervision of an electrician, and in accordance with the rules of

electronics.

1.6.1.3 The machine's electrical equipment must be inspected/checked regularly.

Faults such as loose connections or scorched cables must be corrected

immediately.

1.6.2 Dust

1.6.2.1 When working in close quarters, follow any applicable national

guidelines!

1.6.2.2 Dry cutting is prohibited due to high dust generation.

1.6.3 Noise

1.6.3.1 Wear specified personal hearing protection!

1.7 Transport

1.7.1 Only use lifting gear and load carrying equipment with sufficient lifting

capacity during loading work!

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9

1.7.2 Name expert instructors for the lifting process!

1.7.3 Lift the machine only according to the instructions in the operating

manual (using attachment points for load-bearing systems, etc.), and with

proper lifting accessories!

1.7.4 Only use suitable transport vehicle with sufficient load capacity!

1.7.5 Secure loads reliably. Use suitable attachment points!

1.7.6 Even when moving the machine only for a short distance, disconnect the

machine from the power mains! Before restarting the machine, connect it

to the power mains correctly!

1.7.7 When recommissioning, follow the operating manual!

2. Machine description

2.1 Component overview

Pos. 1 Steering rod

Pos. 2 Control panel

Pos. 3 Driver's seat

Pos. 4 Exhaust (accessory with its own operating manual)

Pos. 5 Diesel tank

Pos. 6 Saw blade protective hood

Pos. 7 Motor housing contents: Diesel engine, controls, hydraulic pump

Pos. 8 Saw head with hydraulic motor, guides and saw blade protective hood

Pos. 9 Undercarriage contents: Steering, gears

Pos. 10 Hydraulic tank

Pos. 11 Attachment points

4 3 2 11

6

8

1

7

11 5 9 10

2.2 Safety equipment

Pos. 6 Saw blade protective hood

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2.3. Technical data

UNICUT 500

Cut depth, max. 380/480 mm (390/490 mm)

Saw blade lifting/lowering Hydraulic cylinder infinitely adjustable

Saw blade diameter, max. 1200 (1000 mm standard)

Saw blade holder -Ø 35 mm (6x M12 TK120)

Drive unit Hydraulically infinitely variable

Cutting gear, forwards/backwards hydraulically infinitely variable 0-70 m/min

Drive motor KUBOTA 4-Cylinder Turbodiesel / EU IIIA

Cooling water cooled

Power 74KW/101PS

Tank capacity of diesel tank 55 litres

Saw blade drive Hydraulic, infinitely adjustable, right/left direction of rotation

107 ccm3 (160 ccm3)

Saw blade speed 800-2100

rpm, electronically infinitely adjustable

Dimensions (L/W/H) 2750 / 965 / 1700 mm

Steering electrical

Left and Right cutting yes

Nominal weight 1630 kg

2.4. Accessories

 Saw blade protective hood  1200mm

 Sludge removal

 see also section 7

2.5. Noise parameters FS 41-5

Guaranteed noise level = 109 dB(A)

Danger! Hearing protection must be worn when exceeding 85 dB(A)!

2.6. Vibration on hand wheel

The total vibration value is under the action value of 2.5 m/s2.

2.7 Whole body vibration on the driver side

Whole body vibration is below the trigger value of 0.5m/s2.

2.8 Water pressure

The water pressure in the lines to the floor cutter must not exceed 5 bar.

Otherwise use a pressure reducer and reduce the water pressure to max.

5 bar.

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3. Commissioning

3.1 Control panel

Before starting the floor cutter become familiar with its operation.

12

26

15

20 24a 13 19

22

24 18 17 16 23

27 28 25 14 21a 21

29

12

Meaning of the symbols:

12. Water pump on-off

13. Motor oil pressure too low (lamps must not be lit)

14. Oil pressure for saw blade motor (max. 400bar)

15. Saw blade speed

16. Emergency stop

17. Battery charging control (lamp must not be lit during operation)

18. Motor cooling water temperature

19. Air filter (must not be lit during operation)

 change dirty cartridges (see 6.3)

20. Operating hours counter

21. Speed control - saw blade motor

22. Saw blade direction of rotation, left and right

23. Exhaust on-off

24. Control system on/off

Control lever for driving direction and cutting gear/fast gear

(must always be in the centre when starting.)

Control lever forward = Forward

Control lever back = Reverse

Button pushed = Fast gear (Point 4.1.2)

Button up = Cutting gear

Note The feed speed is set with the controller

(Pos. 25).

24a. Changing the cutting direction (accessory)

Lever right = normal cutting operation forwards

Lever left = reverse cutting operation

The moving direction of the control lever (Pos. 24) and the running wheel

are switched

25. Feed control cutting operation

26 Gas lever for diesel motor

27. Height adjustment for saw hood

Lever forward = Saw hood up

Lever back = Saw hood down

Lever in the centre = Saw hood stationary

Note The feed speed of the saw hood is also regulated with the lever.

Large deflection = large feed

28. Lever for saw blade height adjustment

Lever forward = Saw blade up

Lever back = Saw blade down

Lever in the centre = Saw blade stationary

29. Ignition switch

30. Plug outlet on the floor cutter

3.2 Connections and operating material

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 The floor cutter is filled with HD oil and diesel fuel at delivery,

however this should be checked.

 All lubrication points are lubricated with Roxana ALU EP2

* HD oil indicator (Pos. 31)

* Tank indicator (Pos. 5)

* Connect cooling water hose (Pos. 32)

3.3 Install saw blade

 All switches on control panel are on "0"

 Start engine with ignition switch (Pos. 29)

 Move saw blade head to the highest position

* Lever pos. 28

Danger! Risk of injury!

Saw blade exchange may only be done with the saw blade at a standstill.

Turn off motor! (Pos. 29)

35

33 34

 Remove ring nut and ring screw (Pos. 33+34)

 Remove exhaust hose and saw hood

 Remove the bolts (Pos. 35)

 Remove pressure disc and insert saw blade

Note Ensure that the flange surfaces are clean.

Match the direction of rotation of the saw blade (arrow on the blade) with

the arrow on the saw hood. (synchronised sawing)

 Mount pressure disc with bolts (Pos. 35)

 Mount saw hood and extraction shoe

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3.4 Preparations for starting

31 36 32

30 37

Note Controller (Pos. 25) is on zero

Control lever (Pos. 24) is in the centre position

 Turn the ignition switch (Pos. 29) until the lamp (Pos. 23) illuminates

(The motor can only be started when the lamp is illuminated)

 Continue to turn the ignition switch (Pos. 29) and start the diesel

motor.

 Moving the floor cutter with the control lever (Pos. 24)

 A pushed in button on the control lever (Pos. 24) means fast gear

without control

 Button up means feed control via the regulator (Pos. 25).

 Move the floor cutter to position

 Steering rod disc and saw blade (or rear steering rod) are above

the cut line

* Couple water hose at position 32 or at the exhaust

 Open water tap (Pos. 36)

 Select the saw blade direction of rotation (Pos. 21a)

 Set diesel engine with accelerator cable (Pos. 26) to "full throttle"

 Set speed with controller (Pos. 21) (see table)

15

 mm 400 500 600 700 800 900 1000 1100 1200 1500  mm

45m/sec.

(concrete)

215

0 1720 1430 1230 1080 960 860 780 720 580 45m/sec.

(concrete)

55m/sec.

(asphalt)

263

0 2100 1750 1500 1310 1170 1050 960 880 700 55m/sec.

(asphalt)

 Switch on the water pump (Pos. 12).

 Slowly initiate lowering movement with lever (Pos. 28) until the saw

blade cuts

Note Is the saw blade getting enough cooling water?

 Set cutting depth indicator (Pos. 37) to "zero"

 Lower saw blade down to the desired cutting depth (mm) (indicator

pos. 37)

 Lever (Pos. 28)

 Set controller (Pos. 25) to “0”

 Slide the control lever (Pos. 24) forwards (button is not pressed!)

 Slowly initiate the feed movement via the controller (Pos. 25)

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4. Transport

4.1 Move in cutting gear or fast gear

4.1.1 Cutting gear

 Control lever (Pos. 24) is in the centre position

 Set controller (Pos. 25) to “0”

 Start engine with ignition switch (Pos. 29)

 Actuate (Pos. 26) accelerator cable

 Determines the highest speed to be reached

 Slide the control lever (Pos. 24) in the desired direction of

movement

 Initiate movement via the controller (Pos. 25)

4.1.2 Fast gear

Only possible if the driver is sitting on the seat

 Process as with 4.1.1 Cutting gear

 In addition the head must be pressed on the control lever (Pos. 24).

Note Regulation via pos. 25 is not possible!

4.2 Moving with the crane

 Is the loading capacity of the crane sufficient?

 Hang a four-way hanger with sufficient loading capacity in the crane

eyes (Pos. 11)

 Lift carefully

Danger! Personnel should never remain under hanging loads

 Always keep an eye on the floor cutter

4.2 Moving with the crane

 Is the loading capacity of the crane sufficient?

 Hang a four-way hanger with sufficient loading capacity in the crane

eyes (Pos. 11)

 Lift carefully

17

5. Operation

5.1 Normal cutting operation

 Preparations for starting (see 3.4)

5.2 Cooling water

 Make sure that the saw blade is supplied with sufficient cooling

water

* Use only clean water

* Do not kink water hose

5.3 Saw blade selection

Refer to the prospect “Lissmac Diamond Tools”. Install only saw blades

recommended by the manufacturer.

5.4 Change from right to left cut

38

18

31 36 32

30 37

 Turn off diesel engine (Pos. 29)

 Remove steering rod (Pos. 1) and cutting depth indicator (Pos. 37)

 Remove the hex hexagon head screws (Pos. 38)

 Swing the complete saw unit to the left side

 Fasten the saw unit with tensioning screw (Pos. 38)

 Mount the steering rod (Pos. 1) and cutting depth indicator (Pos. 37)

on the left side

 Install the driver's seat on the other side

 Swing out control panel

 Do not forget to change the turning direction of the saw blade (Pos.

21 a)

Note If the saw blade is already installed, this must also be rotated (see 3.3).

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6. Maintenance

6.1 Maintenance

first time daily weekly monthly annually

when the

warning

indicator

lights up

every "x"

operating

hours

Cleaning the machine X

Visual inspection for damages X

Check frost protection X

Change hydraulic oil 50 h X 500 h

Change hydraulic filter 50 h X 500 h

Check hydraulic oil level X

Grease lubrication points (nipples) (see 6.3) X X X

Check water supply filter X

Check hydraulic hoses and screwed

connections for leaks and damage

20 h X

Change transmission oil (0.3 l ISO VG 150)

of the wheel hub gear motors

X

Check fill level of the cooling water (see 6.7)

for the diesel motor. X

Check radiator for dirt, clean if necessary. X

Checking the saw head (see 6.6) X

Please follow the operating manual of the motor manufacturer (which is included with each new machine), especially pay attention to the

safety and maintenance procedures (for oil change interval see 6.5)!

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Lissmac UNICUT 500 Owner's manual

Lissmac UNICUT 500 Owner's manual

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