Lissmac UNICUT 500 Owner's manual

Type
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
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
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.
3
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
4
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
6
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!
8
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
10
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.
11
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
13
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
14
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)
16
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).
19
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)!
20
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Lissmac UNICUT 500 Owner's manual

Type
Owner's manual

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