Lissmac COMPACTCUT 400 E User manual

1
ig
OPERATING MANUAL
FLOOR SAW
COMPACTCUT 400 E
LISSMAC Maschinenbau GmbH
Lanzstrasse 4
D-88410 Bad Wurzach
Telephone [phone] / 307- 0
Fax [phone] / 307 - 500
[email protected]
www.lissmac.com
CONSTRUCTION TECHNOLOGY

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3
Imprint The operating manual is valid for:
LISSMAC floor saw
•COMPACTCUT 400 E
Company headquarters:
LISSMAC Maschinenbau GmbH
Lanzstraße 4
D - 88410 Bad Wurzach
Phone: [phone] / 307 – 0
Fax: [phone] / 307 – 500
[email protected]
www.lissmac.com
Translation of the original operating manual
Status: 08-2016
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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BASIC SAFETY INSTRUCTIONS
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.
Handling information for operators
The defined sequence of the handling steps makes proper and safe handling of the machine easier.
•Handling instructions for the operator
The following warning and safety symbols were attached on the machine:
Observe the operating manual
Wear safety glasses and hearing
protection
Warning due to rotating saw blade
Attachment point for crane
transport
High-pressure washing prohibited
Noise power level (noise level) of the machine
Working on the saw blade protective hood is prohibited when the saw blade is running.
Running direction of sawblade
The machine must not be moved when the sawblade is running
Check the drive belts
Disconnect from the power supply during maintenance or when removing the protective hood
Check the running direction, change the phase sequence

5
OPERATING MANUAL
Preface 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 regulations for safety and proper
work are to be observed.
Required tool In order for the floor saw to be operated, a tool - in the form of a saw blade - is required.
These tools can be purchased from the manufacturer.
Changes and reservations We attempt for this operating manual to be correct and up-to-date. To maintain our
technological lead, it can be necessary to change the product without advance notice and
to perform their operation. We accept no liability for malfunctions, breakdowns and
damage caused by this.

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Notes:

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Table of Contents 1. Description of performance.................................................................................................. 8
1.1. Basics of intended use.........................................................................................................9
1.2. Organisational measures ..................................................................................................... 9
1.3. Personnel choice and personnel qualification; basic responsibilities..............................10
1.4. Safety instructions for operation phases .......................................................................... 11
1.4.1. Transport, assembly and installation .......................................................................11
1.4.2. Commissioning..........................................................................................................11
1.4.3. Operation................................................................................................................... 12
1.4.4. Cutting with an open saw blade protective hood. ................................................... 12
1.4.5. Special work while using the machine.....................................................................13
1.4.6. Moving the floor saw................................................................................................13
1.5. Safety instructions for special types of dangers............................................................... 13
1.5.1. Danger for the operator by the machine .................................................................. 13
1.5.2. Electric power ........................................................................................................... 14
1.5.3. Dust ...........................................................................................................................14
1.5.4. Noise ......................................................................................................................... 14
1.6. Transport ............................................................................................................................ 14
1.7. Packaging and Storage ...................................................................................................... 15
1.8. Environmental protection................................................................................................... 15
1.9. Disposal.............................................................................................................................. 15
2. Description of the device.....................................................................................................16
2.1. Name of machine parts......................................................................................................16
2.2. Safety guards .....................................................................................................................16
2.3. Technical data....................................................................................................................17
2.4. Noise power level ..............................................................................................................17
2.5. Hand arm vibration............................................................................................................. 18
2.6. Water pressure................................................................................................................... 18
3. Commissioning ......................................................................................................................19
3.1. Connections and operating materials................................................................................ 19
3.2. Tool selection ..................................................................................................................... 19
3.3. Parking brake......................................................................................................................19
3.4. Install saw blade................................................................................................................ 20
3.5. Changing saw blade direction ...........................................................................................21
3.6. Drive belt ............................................................................................................................22
4. Transport................................................................................................................................23
4.1. Transport position .............................................................................................................. 23
4.2. Move with the crane..........................................................................................................23
4.3. Disassembling the machine............................................................................................... 24
5. Operation................................................................................................................................25
5.1. Safety .................................................................................................................................25
5.2. Preparations for starting ....................................................................................................25
5.3. Moving or setting up the floor saw ...................................................................................25
5.4. Cutting with the floor saw ................................................................................................. 26
5.5. Cutting with an open saw blade protective hood. ............................................................26
5.6. Wall gliding saw hood (optional).......................................................................................27
5.7. Turning of floor saw........................................................................................................... 27
6. Maintenance..........................................................................................................................28
6.1. Service................................................................................................................................ 28
6.2. Troubleshooting table ........................................................................................................ 29
6.3. Torque of screw connections.............................................................................................30
6.4. Maintenance plan ..............................................................................................................31
7. Tools........................................................................................................................................32
8. Conditional connections ......................................................................................................33
9. Warranty ................................................................................................................................34
10. Replacement parts..............................................................................................................35


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1. DESCRIPTION OF PERFORMANCE
Thanks to optimum weight distribution of the COMPACTCUT 400 E, the 7.5 kW/ 400 V electrical
motor ensures an exceptional cutting performance.
•Every corner of the building site can be reached thanks to the compact, easy to handle design
•LISSMAC electrical floor saws are low noise and therefore are particularly suited for cutting
work in and on buildings
•The COMPACTCUT 400 E is fast and can be simply dismantled into three pieces. This means
it can be easily transported inside buildings
•Lowering and raising the saw blade is done smoothly by means of an threaded spindle with
cutting depth display, thereby preventing damage to the saw blade
•Optimum speed of the saw blade shaft
•Saw hood front can be raised for intersections
•Patented flush to wall sawing system with 800 mm wall gliding saw hood (optional) with
flush to wall saw blade holder. Floor cutting flush to walls conforming to the current machine
guidelines or C-standard is guaranteed!
•Exceptional directional stability from the central saw arm position
•The permanently horizontally positioned saw hood offers optimum accident protection and
minimizes spray water loading
•Height adjustable handles
•Easily converted from left to right cut with few hand movements
•The rear running wheel sits outside of the saw cut. This makes recutting of cut joints easy
•Standard flange spraying ensures low water consumption and optimal cooling
•A high slot and saw accuracy is reached due to the optimal weight distribution on the front
wheels

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1.1. Basics of intended use
1.1.1 The warranty obligation of the manufacturer and supplier is voided for improper or non-intended
use. Any change to the machine which is not carried out by the manufacturer is prohibited.
Changes, removal or addition of parts to the floor saw only with the written approval of the
manufacturer.
1.1.2 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.
1.1.3 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.
1.1.4 The LISSMAC floor saw is a floor cutting grinder and is designed exclusively for cutting grooves into
concrete or asphalt using water. Cutting uses saw blades and the machine may only be operated for
cutting of floors. The floor saw may only be operated by one person and is limited by proper
positioning at the rear part of the floor saw. Any other use or use above and beyond is not
considered intended use.
Intended use also includes compliance with the operating manual and observance of inspection and
maintenance manual.
1.1.5 Foreseeable misuse / non-intended use:
Cutting without saw blade protective hood
Cutting without water
Cutting of wood, plastic or metal (except for reinforcement in concrete).
Building changes, which alter the safety or the floor saw design type.
1.2. Organisational measures
1.2.1 The operating manual must be easily accessible for each person at the location of the floor saw.
1.2.2 All additions to the operating manual, all generally valid legal and otherwise binding regulations for
accident prevention and environmental protection are to be followed and instructed!
Such obligations may also apply, for example, to the handling of hazardous materials or the wearing
of personal protective gear or traffic regulations.
1.2.3 Personnel assigned to activities on the floor saw must have read and understood the operating
manual, particularly the Safety Instructions chapter, before starting work. In the middle of work it is
too late. This particularly applies to personnel only occasionally engaged with the crane, such as
those involved in tooling and maintenance.
1.2.4 At least occasionally, perform checks for safe and hazard awareness work by operators while
following the operating manual!

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1.2.5 Use personal protection equipment if necessary or required by regulations!
1.2.6 Keep all safety instructions and danger warnings on the floor saw and in legible condition! Replace
safety and danger instructions, that are damaged or non-readable any more.
1.2.7 For safety-related changes to the machine or its running behaviour, stop the machine immediately
and mark it accordingly. Report the problem to the responsible post/person!
1.2.8 No changes, removal or addition of parts without the written approval of the manufacturer! The
instructions of the tool maker must be followed.
1.2.9 Only use tested original replacement parts from the manufacturer!
1.2.10 Observe required or prescribed deadlines given in the operating manual for inspection.
1.2.11 Workshop equipment suitable for the work is absolutely necessary for performing maintenance
actions.
1.3. Personnel choice and personnel qualification; basic responsibilities
1.3.1 Only qualified personnel 18 years of age or older may operate the floor saw independently. All
personnel must be trained in the operation and be explicitly, in writing, authorized by the company
to operate the floor saw.
1.3.2 Establish responsibilities of the personnel for operating, changeover, servicing, and repairing the
machine!
1.3.3 Make sure that only authorized personnel works at the machine.
1.3.4 The operator must wear personal safety equipment according to the safety regulations, such as
safety shoes, safety gloves and safety glasses.
1.3.5 Remaining in the working area of the floor saw unnecessarily is prohibited! Direct unauthorised
personnel, who are not working on the machine, away from the work area. Block off the working
area, if necessary.
1.3.6 During all movement of the floor saw, operating personnel must ensure that they and other people
are not endangered. All obstacles which may hinder the operation or implementation of the
machine at the location of use must be moved out of the way.
1.3.7 Work on the electrical equipment of the machine may only be carried out by qualified electricians or
trained personnel under the management and supervision of a qualified electrician, and in
accordance with the rules of electronics.
1.3.8 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!

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1.4. Safety instructions for operation phases
1.4.1. Transport, assembly and installation
1.4.1.1 Transport, assembly and installation on/with the floor saw may only be carried out in transport
position. Secure the floor saw against rolling away.
1.4.1.2 Transport, assembly and installation on/with the floor saw may only be carried out with removed
saw blade and when the drive motor is turned off.
1.4.1.3 The transport the floor saw in compliance with the maximum operating weight, this should be
exclusively done by crane.
1.4.1.4 The transport may only be done, as long as all machine parts are tightened on the machine and
individual parts cannot fall.
1.4.2. Commissioning
1.4.2.1 The commissioning of the floor saw may only be carried out in transport position.
1.4.2.2 When inserting the saw blade, observe the running direction. The cutting process must always be
done clockwise, otherwise material is ripped out which causes small pieces of debris to fly around.
1.4.2.3 When inserting the saw blade, protect against sharp edges.
1.4.2.4 Ensure that the floor on which cuts are to be made fulfils load carrying capacities.. All obstacles
must be cleared away from the cutting area and make sure there is sufficient lighting.
1.4.2.5 Visual inspection of the whole floor saw for damages and defects. Special check of the safety
equipment.
1.4.2.6 The steering rod must be set for the operator.
1.4.2.7 Keep water sources handy for cooling the saw blade.
1.4.2.8 No rotating tools which have a maximum rotation speed smaller than the nominal speed of the
machine can be used.
Defective or broken tools must be replaced immediately.

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1.4.3. Operation
1.4.3.1 Refrain from working in any manner that is questionable in regard to safety!
1.4.3.2 Take measures to ensure that the floor saw is operated only in a safe, functional condition!
1.4.3.3 The floor saw must be checked at least once per shift for externally identifiable defects or
damages! 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 against
restart!
1.4.3.4 Immediately stop and secure the floor saw in case of malfunctions! Immediately correct
malfunctions! Electrical work may only be carried out by qualified electricians.
1.4.3.5 Only suitable and tested tools must be used.
1.4.3.6 For protection before acceleration, move the depth setting of the saw blade slowly into the solid
floor. Avoid any contact with the running tool.
1.4.3.7 It is prohibited to cut without the saw blade protective hood or the drive motor cover. The operator
must be protected by turning parts.
1.4.4. Cutting with an open saw blade protective hood.
1.4.4.1 Removing or opening of the saw blade protective hood or reaching into the saw blade during
cutting is prohibited. This work may only be carried out with the saw blade at a standstill and the
drive motor turned off.
1.4.4.2 When cutting with an opened saw blade protective hood folded open the saw blade does not
cover the front area. Particular care is necessary!

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1.4.5. Special work while using the machine
1.4.5.1 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 technical personnel.
1.4.5.2 Inform operating personnel before beginning special and maintenance work! Name a supervisor!
1.4.5.3 If the floor saw is turned off during maintenance and repair work, it must be secured against
unexpected application of power.
1.4.5.4 Before cleaning all openings in which no cleaning agent should penetrate due to safety and/or
functional reasons must be covered and glued. Electric motors, switches and plugs are especially
at risk. After cleaning, remove the covers/tape completely!
1.4.5.6 During service and repair work, always tighten loose bolt joints!
1.4.7.7 If dismantling is required for fitting, servicing and repair, the safety fittings must be remounted
and checked immediately following the service and repair work!
1.4.7.8 No rotating tools which have a maximum rotation speed smaller than the nominal speed of the
machine can be used.
1.4.6. Moving the floor saw
1.4.6.1 The floor saw may only be moved when the saw blade is at a standstill.
1.4.6.2 Before leaving the operating position on the floor saw, the drive motor must be shut down and the
saw blade must no longer rotate.
There is a danger of injury by a rotating saw blade.
1.4.6.3 The operator may not leave the floor saw if the parking brake has not been activated. The floor
saw must be secured against rolling away.
1.5. Safety instructions for special types of dangers
1.5.1. Danger for the operator by the machine
1.5.1.1 Before leaving the operating position on the floor saw, the drive motor must be shut down and the
saw blade must no longer rotate.
There is a danger of injury on a rotating saw blade.
1.5.1.2 Working on the floor saw and moving with rotating saw blade is prohibited.
1.5.1.3 The drive motor of the floor saw must only be put in operation for intended use cutting.

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1.5.2. Electric power
1.5.2.1 Use only original fuses with the specified current rating! In case of malfunctions, turn the floor
saw off immediately! Electrical work may only be carried out by technical and qualified personnel.
1.5.2.2 Carry out maintenance or repair work only when the motor of the floor saw is turned off and the
saw blade is not running any more. Transport position requires special care.
1.5.2.3 The machine's electrical equipment must be inspected/checked regularly. Faults such as loose
connections or damaged cables must be corrected immediately. The machine must be labeled so
that it cannot be started by others.
1.5.3. Dust
1.5.3.1 When working in close quarters, follow any applicable national guidelines!
15.3.2 To prevent dust build-up during cutting, the saw blade must be cooled using water. Dry cutting is
prohibited and damages not only the saw blade.
1.5.4. Noise
1.5.4.1 See 2.4 Noise power level of the machine
1.6. Transport
1.6.1 To implement using a crane, slinging equipment with sufficient load carrying capacity must be
used. Slinging equipment must be checked for damage before use.
1.6.2 Name expert instructors for the lifting process!
1.6.3 Lift the floor saw only according to the instructions in the operating manual and with proper lifting
gear!
1.6.4 Only use suitable transport vehicle with sufficient load capacity!
1.6.5 Secure loads reliably according to the regulations. Use suitable attachment points!
1.6.6 Even when moving only for a short distance, the motor of the floor saw must be turned off. The
saw blade may not be rotating before a restart!
1.6.7 When recommissioning, follow the operating manual!

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1.7. Packaging and Storage
To ensure sufficient protection during shipping and transport, the machine and its components are
carefully packaged. When receiving the machine, the machine should be checked for damage. The
packaging of the device consists of materials which can be recycled. Put these by type into the
relevant recycling containers, so that they can be recycled properly.
In the case of damage, the machine must not be put into operation. Even damaged cable and plugs
represent a safety risk and must not be used. In this case, please contact the manufacturer.
If the machine is not immediately put into operation after unpacking, it must be protected from
moisture and dirt.
1.8. Environmental protection
Packaging material, cleaning agents, used or residual operating materials, as well as removed
wear parts, such as drive belts or motor oils must be taken to recycling corresponding to the valid
regulations for environmental protection at the place of use.
1.9. Disposal
If the expiry date of the device has been reached, in particular if functional errors happen, make
the used machine unusable.
Dispose of the device according to the valid regulations for environmental protection of your
country. Electrical waste may not be disposed of in household waste. Take the used device to a
central rubbish collection centre.

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2. DESCRIPTION OF THE DEVICE
2.1. Name of machine parts
Pos. 1 Water hose Pos. 8 Saw blade
Pos. 2 Saw arm Pos. 9 Steering rod
Pos. 3 Handle Pos. 10 Fold up part of the saw blade protective hood
Pos. 4 Handle (height adjustment) Pos. 11 Parking brake
Pos. 5 Saw blade protective hood Pos. 12 Thumb screw for table foot adjustment
Pos. 6 Spray protection Pos. 13 Thumb screw for the handle
Pos. 7 Flange cover of the saw blade protective hood
2.2. Safety guards
Pos. 5 Pos. 6 Spray protection
3
6
5
10
1
7
8
9
4
2
13
12
11

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2.3. Technical data
COMPACTCUT 400 E
Max. cutting depth 320 mm
Max. saw blade diameter 800 mm
Saw blade holder 25.4 mm
Saw blade speed 1250 1/min
Operating weight 167 kg
Left/right cut yes
Drive motor Electric motor
Power consumption 400V / 16.1 A
Power supply 3PH + N + PE
Power (kW/PS) 7.5 kW
Dimensions (min.) L/W/H 1200 / 650 / 1090 mm
2.4. Noise power level
Danger! In an environment with a high noise level, for example when working near loud machinery,
wearing hearing protection in the workplace is prescribed for above 85 dB(A).
The details define volume of noise level, related to the operator workspace and the noise power
level of the floor saw.
The measured noise level L
wA
95 dB(A)
The emission noise pressure at the operator's place L
pA
96 dB(A)
The guaranteed noise power level is:
COMPACTCUT 400 E 96 dB(A)
The values are determined by the noise emission measurement.
Testing is done under load with the largest permitted saw blade of the floor saw.
Measurement tolerances:
2.5 dB for the A-value noise power level
4 dB for the A-value emission noise pressure level
Emission noise pressure is done in compliance with
EN ISO 3744, EN 13862 and guidelines 2000/14/EC.

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2.5. Hand arm vibration
The given value was determined with the maximum saw blade diameter.
The impact can be reversely proportional to the weight of the operator.
Total vibration value:
COMPACTCUT 400 E a HV less than 2.5 m/s
2
The following standards were complied with during measurement:
EN ISO 5349, VD 2057 Sheet 2, Directive 2002/42/EC.
The given values were measured during concrete cutting at a cut depth of 5 cm.
In practice, these values are influenced by the following conditions:
•Quality of the saw blade
•Number of saw blades
•Weight of the operator
•Feed speed
•Condition of the machine
•Concrete properties
2.6. Water pressure
Note The water pressure in the lines to the floor saw 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. Connections and operating materials
Connection of electricity
A reliable power source with an operating voltage and corresponding fuses as shown on the
model plate must be available.
Water spray
To prevent dust build-up during cutting, the saw blade must always be cooled using water. Dry
cutting is prohibited!
Lubrication points
Moving parts must be lubricated on the lubrication points of the floor saw at regular intervals.
The manufacturer uses a qualified heat-resistant multi-purpose grease.
3.2. Tool selection
Danger! The use of non-tested or unauthorised tools such as cutting wheels or circular saw blades is
prohibited. Damaged tools must not be used!
All tools in the area of diamond tools are marked in colours. Depending on the application
purpose and area, tools are different. To have the best results, the parameters must match.
Storage of tools
Tools must be protected against humidity during storage. The applied segments around the saw
blade must be protected from damage.
Note In the LISSMAC sales booklet, the prices for the tools are determined. This sales booklet can be
obtained from the manufacturer at any time.
3.3. Parking brake
Danger! In order to secure the floor saw against rolling away, the parking brake must be used.
The parking brake is set via the height adjustment of the saw arm.
Loosen the spring lock on the crank and turn it into the upper position
The parking brake presses on the wheel of the floor saw and prevents it from rolling
away
Secure the height adjustment via the spring lock

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3.4. Install saw blade
Danger! Removing or opening of the saw blade protective hood or reaching into the rotating saw blade
during cutting is prohibited. These works may only be carried out with the saw blade at a
standstill and the drive motor turned off.
Note No rotating tools which have a maximum rotation speed smaller than the nominal speed of the
machine can be used.
Defective or broken tools must be replaced immediately.
In order to change the saw blade, the following steps must be carried out:
Rotate the saw arm to the uppermost position above the crank (Pos. 1)
Remove the hexagon head screw (Pos. 2)
Remove the flange nuts using the tool kit (SW36) and remove the pressure disc
Note When installing the saw blade, ensure that the flange surfaces are clean. The saw blade must sit
directly on the flange. Match the direction of rotation of the saw blade with the rotation direction
arrow (synchronised sawing) on the saw blade protective hood.
Insert saw blade
Install the pressure disc and flange nut
Insert the locking pin
Remove the flange nuts using the tool kit (SW36) and remove the pressure disc
Plug-in the saw blade protective hood
1
2
3 4