Husqvarna Fs 4800 D Manual
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51 • P u s h t h e S P E E D C O N T R O L LEVER (1O) forward for FORWARD saw movement, or to the rear for R E V E R S E s a w m o v e m e n t . T h e further you push the lever the faster the speed. DO NOT OPEN the TRANSMISSION BYPASS VALVE (6J) to neutral while the saw is parked on a grade (or hill), The Operator will lose control and injury or damage could occur. R e a r P i v o t M o d e l ( w i t h D i f f e r e n t i a l S y s t e m – If equipped) Moving The Saw With The Engine Off: • Tu r n E N G I N E S TA RT S W I T C H ( 1 H ) t o t h e “ 1 ” (RUN) position. • Raise the saw by pressing up on the TOGGLE SWITCH (1P) on the SPEED CONTROL LEVER (1O) until the DIAMOND BLADE (2E) (if installed) clears the pavement surface. • Tu r n E N G I N E S TA RT S W I T C H ( 1 H ) t o t h e “ 0 ” (STOP) position. • Put the SPEED CONTROL LEVER (1O) into the STOP POSITION (1BB). • P r e s s a n d h o l d t h e D i f f e r e n t i a l S w i t c h ( 1 J ) t o the Right. • Hold one Handle Bar (1B), and Press and hold the Differential Switch (1J) to the Right. The saw can now be moved by standing behind it and pushing. If the Differential Switch (1J) is released, the saw can not be moved with the engine off. DO NOT attempt to push the saw while it is in NEUTRAL on a grade (or hill). The saw operator could lose control of the saw and cause injury to himself or other persons in the area. Moving The Saw With Engine On: • R a i s e t h e s a w b y p r e s s i n g u p o n t h e TO G G L E SWITCH (1P) on SPEED CONTROL LEVER (1O) until DIAMOND BLADE (2E) (if installed) clears the pavement surface. • Set the WATER SAFETY SWITCH (1L) button to the “0” (OFF) position. • SPEED CONTROL LEVER (1O) must be in the STOP POSITION (1BB) to start the saw. The engine WILL NOT start unless the SPEED CONTROL LEVER (1O) is in the STOP (1BB) position. • T u r n t h e E N G I N E T H R O T T L E ( 1 F ) t o a l o w speed setting. • Set the BLADE CLUTCH SWITCH (1V) (if equipped) to “0” (OFF). * In cold conditions (below 32° F (0° C)) push in on the ENGINE START SWITCH (1H) for 15 seconds. This preheats the engine for cold weather starting. • Turn the ENGINE START SWITCH (1H) to the “2” (START) position until the engine starts, then release the switch. It will return to RUN position. If the engine does not start, repeat these steps. 3 Transport (Blade Removed) (See Figures 1, 2, and 5) Turn engine off. Set SPEED CONTROL LEVER (1O) to STOP POSITION (1BB). Remove DIAMOND BLADE (2E) before transport. When moving the saw up and down ramps, with engine on, use extreme caution. • To go DOWN a ramp drive the saw FORWARD slowly. • To go UP a ramp, back the saw in REVERSE slowly. Rear Pivot Model: Machine must have DIFFERENTIAL SWITCH (1J) in the center “Lock” position if moving saw up or down ramps! DO NOT shift DIFFERENTIAL SWITCH (1J) to the Left “Pivot” position if moving the saw up or down ramps! For steep ramps, always use a winch. Never stand below the machine. Lifting the Saw: The saw can only be lifted by the factory installed Lifting Bail (6A). To Transport By Vehicle: • Set ENGINE START SWITCH (1H) in the OFF position. • Set SPEED CONTROL LEVER (1O) in the STOP POSITION (1BB). • Push Handle Bars (1B) inward and tighten Knobs (1A). Block the saw in place or secure it into place using the factory installed TIE DOWN LUGS (3-1H, 3-2H), front and rear to prevent movement during transport. 4 Check Before Starting Take into account the working conditions from health and safety point of view. • Fuel (Check the engine maintenance manual.) Use No. 2 Diesel Fuel for normal conditions. Fill tank at FUEL TANK FILL (5E) location. • Check that the engine oil level is correct. Because the engine often operates at an angle, check the oil level (with engine horizontal) frequently to ensure that the oil level never falls below the lower mark on the ENGINE OIL DIPSTICK (5B). SAE 15W40 CF, CF-4, CG-4, or CI-4 engine oil is recommended. • For start up, refer to the Yanmar engine manual. • Push the SPEED CONTROL LEVER (1O) forward for FORWARD saw movement, or to rear for REVERSE saw movement. The further you push the lever the faster the speed.
52 Do not operate this saw without the GUARD SPADE LATCH (2L) engaged and the bolt [18”- 30” (450-700mm) Blade Guards] installed. Inspect blade guards and latches frequently. Do not use if damaged. To Remove A SLIP-ON GUARD: • Using the BLADE SHAFT WRENCH (2J) remove the rear retaining bolt [18”-30” (450-700mm) Blade Guards]. • For 14-30” (350-700mm) Blade Guards: Use the WIRE LANYARD (2K) to open the BLADE GUARD SPADE LATCH (2L). • For 36” (900mm) Blade Guards: BLADE SHAFT WRENCH (2J) is used to pivot the BLADE GUARD SPADE LATCH (2L) to the open position. • Lift guard off spade. To Install A SLIP-ON GUARD: • Lower guard onto spade until BLADE GUARD SPADE LATCH (2L) engages. • Install REAR BOLT (2M) [14”-30” (350-700mm) Blade Guards] in rear of guard using the BLADE SHAFT WRENCH (2J). • Verify that machine is set up correctly for the DIAMOND BLADE (2E) diameter required for the job. Check that the correct Engine GEARBOX PULLEY (3-1N, 3-2N), BLADE SHAFT PULLEY (3-1L, 3-2L), BLADE FLANGE (2B & 2F), and BLADE GUARD (2H) are installed. For machines equipped with the three-speed ENGINE GEARBOX (3-2A), also check that the GEARBOX SHIFT LEVER (3-2P) is in the correct gear. See SECTION 14, “Engine / Blade Shaft / Gearbox Speed Adjustment”, for more details. 5 Fitting The Blade (See Figures 1 and 2) • Set ENGINE START SWITCH (1H) to “1” position. • R a i s e M a c h i n e t o a h i g h p o s i t i o n u s i n g t h e TOGGLE SWITCH (1P) on the SPEED CONTROL LEVER (1O). • Set the ENGINE START SWITCH (1H) to the “0” (OFF) position. • Loosen Bolt on BLADE GUARD NOSE LATCH (2G). • Raise Front Half of BLADE GUARD (2H). • L o o s e n B l a d e s h a f t B o l t ( 2 A ) R e m o v e O U T E R FLANGE (2B). • F i t D I A M O N D B L A D E ( 2 E ) t o O U T E R F L A N G E ARBOR (2C). • Install OUTER FLANGE (2B) into the BLADE SHAFT (2I) making sure that the LOCKING PIN (2D) passes through the DIAMOND BLADE (2E) and into the INNER FLANGE (2F). Note the direction of rotation of the blade. The direction of rotation is shown by an arrow on both the DIAMOND BLADE (2E) and the BLADE GUARD (2H). Make sure that the contact surfaces on the DIAMOND BLADE (2E), INNER & OUTER FLANGES (2B & 2F) and OUTER FLANGE ARBOR (2C) are clean. • R o t a t e O U T E R F L A N G E ( 2 B ) a n d D I A M O N D BLADE (2E) in the opposite direction of blade rotation to remove backlash. • Install and tighten Blade Shaft Bolt (2A) while firmly holding the DIAMOND BLADE (2E). Tighten using the BLADE SHAFT WRENCH (2J) provided. • Lower front half of BLADE GUARD (2H) and tighten the Bolt on the BLADE GUARD NOSE LATCH (2G). The Blade Shaft Bolt (2A) on the Right Hand side has Left Hand threads. The Blade Shaft Bolt (2A) on the Left Hand side has Right Hand threads. Slip-On blade guards are provided with a safety BLADE GUARD SPADE LATCH (2L) which engages the support spade and a REAR BOLT (2M) [18”-30” (450-700mm) Blade Guards], to retain the rear of the guard. 6 Starting The Saw (See Figures 1, 2 and 5) Always pay extreme care and attention to the preparation of the machine before starting. Remove all wrenches and tools from the floor and the machine. Always keep blade guard, belt guards and fan guards in place. • Follow all operating instructions and warnings in this manual and on the machine. • Close the WATER VALVE (1T). • Mark the surface to be cut by drawing a line where the cut is to be made. • Pull out Handle Bars (1B) to desired length and tighten Knobs (1A). • Lower the Front Guide (6D) and align the Front Guide (6D), Rear Guide (6F) and DIAMOND BLADE (2E) with the line on the surface. • To start the saw when no water pressure is present, set the WATER SAFETY SWITCH (1L) to “0” (OFF). • Set SPEED CONTROL LEVER (1O) to the STOP POSITION (1BB). Saw will not start unless the SPEED CONTROL LEVER (1O) is in the STOP POSITION (1BB). Check to be certain the TRANSMISSION BYPASS VALVE (6J, Front Pivot Models Only) is closed in the down position. • Set the BLADE CLUTCH SWITCH (1V) (if equipped) to “0” (OFF).
53 • Start the engine using the ENGINE START SWITCH (1H). Follow the procedure in the engine manual. In Cold conditions, pre-heat the engine by holding in the ENGINE START SWITCH (1H) for 15 seconds. • Let the engine warm up for several minutes with ENGINE THROTTLE (1F) at the low speed setting. • When ready, open the WATER VALVE (1T). • Set WATER SAFETY SWITCH (1L) to “1” (ON). Test for adequate water supply. (2.5 - 5.0 GPM) (10 - 20 Liters per Minute) Low water flow will cause damage to diamond blades. • For Machines without the Optional BLADE CLUTCH SWITCH (1V): Pull ENGINE THROTTLE (1F) out to set engine RPM at 3200, as shown on the ENGINE TACHOMETER (1G). See chart for the appropriate blade shaft and engine speeds for specifc blade sizes. • Move the saw forward or reverse (Standard and Front Pivot Models) slowly by pushing or pulling on the Speed Control Lever (1O). Move the saw slowly to prevent stalling the blade. Make sure the Front Guide (6D), Rear Guide (6F) and DIAMOND BLADE (2E) stay on the line. Rear Pivot Model Only: For the Rear Pivot Model, aligning to the cutting line can be made using the pivot feature on the machine. Simply move the DIFFERENTIAL SWITCH (1J) to the Left position (Pivot), and then use both hands to push down on the HANDLEBARS (6G), and the machine can be pivoted from side to side to align with the cutting line. After the saw is properly aligned to the cutting line, toggle the DIFFERENTIAL SWITCH (1J) to the Center (Lock) position. • Set the BLADE CLUTCH SWITCH (1V) (if equipped) to “1” (ON) to engage the Blade Drive when engine is at IDLE SPEED (1200 RPM or less)! When clutch engages and blade is at idle speed, pull out ENGINE THROTTLE (1F) and set engine RPM at 3200. • Lower the saw by pressing the TOGGLE SWITCH (1P) on the SPEED CONTROL LEVER (1O) downward until the DIAMOND BLADE (2E) is at the desired cutting depth (See “Blade Cutting Depth Information”). Be certain that water flow is abundant for wet sawing. Blade Cutting Depth Information: The saw is equipped with a BLADE DEPTH INDICATOR (1Q) which has two number ranges. The Orange and White number ranges are used for two different purposes: 1) The “Depth” number range, indicated by the Orange color, shows the current Cutting Depth of the DIAMOND BLADE (2E). As the saw is lowered, the BLADE DEPTH INDICATOR (1Q) needle travels through these numbers in increasing order. Or 2) The “SMD” or “Set Maximum Depth” number range, indicated by the White color, is the uncut depth of the DIAMOND BLADE (2E). The desired maximum cutting depth is pre-set using the BLADE DEPTH INDICATOR (1Q). It can be used with or without the BLADE DEPTH STOP SWITCH (1M) feature. As the saw is lowered, the BLADE DEPTH INDICATOR (1Q) needle travels through the White color number range in decreasing order, indicating the unfinished depth of cut. When the BLADE DEPTH INDICATOR (1Q) needle reaches “0” position, the desired maximum cutting depth is reached. If the BLADE DEPTH STOP SWITCH (1M) feature is used (“1” or “ON” position), the lowering process stops automatically. Using the BLADE DEPTH INDICATOR (1Q): “Depth” Mode (Orange colored numbers show current cutting depth): • Turn ENGINE START SWITCH (1H) to “0” (OFF) position to STOP engine (If running). • Turn ENGINE START SWITCH (1H) to “1” (RUN) position to power electrical system. • Turn BLADE DEPTH STOP SWITCH (1M) to “0” (OFF) position. • Lower DIAMOND BLADE (2E) by pushing the TOGGLE SWITCH (1P) on the SPEED CONTROL LEVER (1O) downward until the DIAMOND BLADE (2E) touches the surface to be cut. • Rotate the BLADE DEPTH INDICATOR (1Q) needle to align to the “0” depth. • As DIAMOND BLADE (2E) is lowered into the cutting surface, the current cutting depth will now be indicated by the Orange text number range on BLADE DEPTH INDICATOR (1Q) needle. S M D o r “ S e t M a x i m u m D e p t h ” M o d e w i t h o u t BLADE DEPTH STOP (White colored numbers show uncut depth): • Turn ENGINE START SWITCH (1H) to “0” (OFF) position to STOP engine (If running). • Turn ENGINE START SWITCH (1H) to “1” (RUN) position to power electrical system. • Lower DIAMOND BLADE (2E) by pushing TOGGLE SWITCH (1P) on the SPEED CONTROL LEVER (1O) downward until DIAMOND BLADE (2E) touches the surface to be cut. • Rotate the BLADE DEPTH INDICATOR (1Q) needle to align with the desired maximum cutting depth on White colored number range. The uncut depth will now be indicated on the White colored number range. When the BLADE DEPTH INDICATOR (1Q) needle gets to the “0” position, the saw is cutting at the desired maximum cutting depth. • Raise the blade by pushing the TOGGLE SWITCH (1P) on the SPEED CONTROL LEVER (1O) upward until the DIAMOND BLADE (2E) is off of the cutting surface. • Turn the ENGINE START SWITCH (1H) to the “0” (OFF) position to turn off power to electrical system.
54 7 Stopping The Saw (See Figures 1-2) For EMERGENCY STOP, press down on the RED PALM SWITCH (1k) on the cowl. This will stop the engine and disconnect power to all electrical items except lights. Reset the RED PALM SWITCH (1k) by pulling out until it pops up, then restart engine. • Move the SPEED CONTROL LEVER (1O) to the STOP POSITION (1BB). • Raise the DIAMOND BLADE (2E) out of the cut by pressing the TOGGLE SWITCH (1P) on the SPEED CONTROL LEVER (1O) upward until the DIAMOND BLADE (2E) clears the surface. • D i s e n g a g e t h e B L A D E C L U T C H S W I T C H ( 1 V ) (if equipped). • Tu r n t h e E N G I N E T H R O T T L E ( 1 F ) t o t h e L O W IDLE position. SMD or “Set Maximum Depth” Mode using BLADE DEPTH STOP SWITCH (1M) (White colored numbers show uncut depth): • Turn ENGINE START SWITCH (1H) to “0” (OFF) position to STOP engine (If running). • Set the BLADE DEPTH STOP SWITCH (1M) to the “0” (OFF) position to override the depth stop setting. Saw will raise and lower over its full range without stopping. • Turn ENGINE START SWITCH (1H) to “1” (RUN) position to power electrical system. • Lower DIAMOND BLADE (2E) by pushing TOGGLE SWITCH (1P) on the SPEED CONTROL LEVER (1O) downward until DIAMOND BLADE (2E) touches the surface to be cut. • Rotate the BLADE DEPTH INDICATOR (1Q) needle to align with the desired maximum cutting depth on White colored number range. • Set the BLADE DEPTH STOP SWITCH (1M) to “1” (ON) position. • Raise the blade by pushing the TOGGLE SWITCH (1P) on the SPEED CONTROL LEVER (1O) upward until the DIAMOND BLADE (2E) is off of the cutting surface. • Turn the ENGINE START SWITCH (1H) to the “0” (OFF) position to turn off power to electrical system. • Now the maximum cutting depth is set. If the saw is raised out of the cut surface for any reason it can now be lowered to “Set Max. Depth” by lowering the blade until the saw lowering movement stops. The saw WILL NOT lower to any depth greater than the position set on the BLADE DEPTH STOP SWITCH (1Q). If a deeper cut is required, the BLADE DEPTH INDICATOR (1Q) MUST be turned to the new depth position. Or push the BLADE DEPTH STOP SWITCH (1M) to “0” (OFF) position to override the Depth Stop Feature. • Turn off the WATER VALVE (1T). • Let the Engine run at idle for a few minutes before shutting off. • STOP the engine by turning the ENGINE START SWITCH (1H) to the “0” (OFF) position. 8 Incidents During Sawing (See Figures 1-2) If ENGINE STOPS during sawing, check the following: • Engine out of fuel — Check Fuel Level at FUEL TANK FILL (5E) or at fuel level gauge at rear of machine. • Lack of water signals the WATER SAFETY SWITCH (1L) to stop the engine. Set WATER SAFETY SWITCH (1L) to “0” (OFF) and then restart the engine. • Excessively fast cutting speed will stall engine. • RED PALM SWITCH (1K) has been pressed down. Reset by pulling switch until it pops upward. • CIRCUIT BREAKER (1Z) is tripped. Push to Reset I f t h e D I A M O N D B L A D E ( 2 E ) S T O P S d u r i n g sawing, check: • Drive belt tension is inadequate. • The BLADE CLUTCH SWITCH (1V) has been pushed to “0” OFF • The BLADE CLUTCH (1V) (if equipped) has an electrical failure or blown fuse. SAW LOWERS TOO FAST: • The lowering rate of the saw can be adjusted using the SAW LOWERING SPEED CONTROL KNOB (1U) at the rear of the saw. If the saw falls too quickly, turn the knob on the SAW LOWERING SPEED CONTROL KNOB (1U) CLOCKWISE until an adequate lowering rate is set. If the ENGINE or BLADE STALLS, for any reason, raise the blade completely from the cut, inspect the machine thoroughly before restarting the engine. When lowering the blade into a partial cut, align the blade exactly with the cut to prevent damage to the blade. E n t r u s t a l l r e p a i r s t o y o u r a u t h o r i z e d dealer only. 9 Adjustments: Straight Line Sawing (See Figures 1 and 4) While cutting, the saw may steer to the right from the required straight line marked on the cutting surface (if the DIAMOND BLADE (2E) is installed on the right hand side). If this occurs, the Rear Axle (4E) of the saw can be pivoted to compensate for this situation. Front Pivot Model (Saw with Electric Tracking option): • Push AXLE ADJUSTMENT SWITCH (1J) to the LEFT. Small short adjustments make large changes.
55 • Adjustments can be made while sawing or not sawing. • Visually confirm the axle movement and direction. Standard Model Saw with Manual Axle Adjustment • The axle (4E) is adjusted by turning the M12 MANUAL AXLE ADJUSTMENT BOLT (1CC) located at the rear lower left of saw frame. • If the saw steers to the RIGHT while sawing, turn t h e M A N U A L A X L E A D J U S T M E N T B O LT ( 1 C C ) COUNTERCLOCKWISE. • I f t h e s a w s t e e r s t o t h e L E F T w h i l e s a w i n g , t u r n t h e M A N U A L A X L E A D J U S T M E N T B O LT (1CC) CLOCKWISE. Rear Pivot Model (Saw with Differential Pivot option): • Simply bear against the HANDLEBARS (6G) to hold the saw on the cutting line. DO NOT shift the DIFFERENTIAL SWITCH (1J) from the Center “Lock” position. The Left, “Pivot”, position of the DIFFERENTIAL SWITCH (1J) is NOT for adjusting the straight line sawing of the saw. 10 Maintenance (See Figures 1-6) Before performing any maintenance, ALWAYS park the machine on a level surface with the Engine OFF and the ENGINE START SWITCH (1H) in the “0” (OFF) position. After each use CLEAN the machine. LUBRICATION: ENGINE OIL: Check daily (5B). Change Engine Oil and ENGINE OIL FILTER (5D) after every 100 HOURS of operation. See engine manual for recommended oil. SAE 15W40 API Class CF, CF-4, CG-4, or CI-4 engine oil is generally recommended. Capacity is 7.8 quarts (7.4 liters) with ENGINE OIL FILTER (5D). Align oil level with upper mark on ENGINE OIL DIPSTICK (5B). Use ENGINE OIL DRAIN VALVE (3-1I, 3-2I) to drain engine oil: • Remove DIAMOND BLADE (2E), and then lower saw to a horizontal position. • Raise and secure ENGINE HOOD (6E). • Put a container, large enough to contain the engine oil capacity, near the end of the oil drain hose. Open ENGINE OIL DRAIN VALVE (3-1I, 3-2I) and allow contents to drain into the container. Dispose of the used engine oil in an environmentally safe manner. Securely close ENGINE OIL DRAIN VALVE (3-1I, 3-2I). Fill with recommended oil until oil level aligns with the upper mark on ENGINE OIL DIPSTICK (5B). LUBRICATE EVERY 100 HOURS: • Front Axle Pivot Bearings (4C) LUBRICATE EVERY 250 HOURS: • Bladeshaft Seals and Bearings (4A) 2 Pumps only HYDRAULIC SYSTEM: Refer to Section 12 -“Hydraulic System” ENGINE GEARBOX (3-1A, 3-2A): • Change oil after every 500 hours of operation. Use SAE 75W90 synthetic gear lubricant. DO NOT OVERFILL! Fill only to “Check Port” or excess will overflow. Single Speed ENGINE GEARBOX (3-1A): Oil Capacity is 32 oz. (USA) (0.946 Liter) Three Speed ENGINE GEARBOX (3-2A): Oil Capacity is 60 oz. (USA) (1.77 Liter) • Drain cooling water from Water Drain Valve (3-1C, 3-2C) to prevent rust and freeze damage (Every Day). COOLING SYSTEM: The engine cooling fluid is 50/50 anti freeze/water mixture. See engine manual for recommendations. • Clean the RADIATOR AIR FILTER ELEMENT (1DD) every 50 hours or when required, replace if damaged. Always keep RADIATOR AIR FILTER ELEMENT (1DD) in place. • Check hoses and hose clamps for damage and looseness. Tighten or replace as required. • Check Coolant Freeze Protection yearly. • Flush and Clean radiator and cooling system every 500 hours. • Maintain at least 1/4 full coolant level in RADIATOR COOLANT OVERFLOW BOTTLE (1Y) when engine is cool. AIR FILTER: • Clean the Air Filter Outer Element (5A) when the AIR RESTRICTION INDICATOR (1N) Red Signal appears. DO NOT clean the Inner Safety Element (5A)! To change or clean the air filter element: • Remove the Air Filter Housing (5A) by opening the two (2) Air Filter Housing Clamps, and pulling the housing off. • Pull the Air Filter Outer Element out of the filter housing and replace, or clean by using low pressure compressed air [2.75 bars (40 psi) - MAXIMUM)] from the inside out. DO NOT clean the filter element by tapping it on the ground or other objects, this will damage the filter element! • Install the new or cleaned Air Filter Outer Element by pushing it into the housing. • Install the Air Filter Housing (5A) and close the two (2) Air Filter Housing Clamps (5A). The two (2) Air Filter Housing Clamps (5A) can NOT be closed unless the Air Filter Outer Element is properly installed.
56 13 Important Advice (See Figures 2-3) • Tighten loose nuts and bolts regularly, particularly after several hours of operation. • Check V-BELTS (3-1M, 3-2M) tension regularly. Re-tighten V-BELTS (3-1M, 3-2M) as necessary. • Remove the DIAMOND BLADE (2E) for storage. Store it carefully. • Check the water spray over the DIAMOND BLADE (2E) periodically. • Tighten the DIAMOND BLADE (2E) firmly on the OUTER FLANGE ARBOR (2C). • Make sure the contact faces of FLANGES (2B & 2F), DIAMOND BLADE (2E), and BLADE SHAFT (2I) are clean. Store in a safe place out of reach of children. Remove all adjustment tools and wrenches. Store diamond tool in a safe place so it 11 Blade Shaft V-Belt Tension (See Figures 1-3) This saw is equipped with high tension banded V-belts. The belts are properly tensioned at the factory but after a few hours of operation they will stretch and become loose. Re-tension belts as described below. To Tension V-Belts: • Turn ENGINE START SWITCH (1H) to the “0” (OFF) position. • Open ENGINE HOOD (6E) by turning each of the two (2) HOOD LATCHES (3-1D, 3-2D) counter clockwise for 180 degrees. For European CE models, a tool, such as a screw driver must be used to open these latches. Rotate the ENGINE HOOD (6E) upward, and secure it in the open position using the HOOD SUPPORT (6H). • Using the BLADE SHAFT WRENCH (2J), loosen the horizontal clamping bolts (3K) at the front of the machine. • Turn each of the two (2) vertical BELT TENSIONING BOLTS (3-1J, 3-2J) [at the front of machine, below the ENGINE GEARBOX (3-1A, 3-2A)] CLOCKWISE until the V-BELTS (3-1M, 3-2M) are tight. • Replace V-BELTS (3-1M, 3-2M) in complete sets only. • For optimum V-Belt tension use Goodyear TensionRite™ Strips, P/N 542 19 13-68. TensionRite™ strips are supplied with belts purchased from your dealer. • Never tension V-BELTS (3-1M, 3-2M) beyond the original factory tension. Loose V-Belts result in poor saw performance and short belt life. Replace all shields and guards. Never run Saw with out all shields and guards in place. 12 Hydraulic System (See Figures 1-6) The hydraulic system on this saw is used to RAISE / LOWER the DIAMOND BLADE (2E), and to propel the saw FORWARD and REVERSE. The hydraulic system consists of a HYDROSTATIC TRANSMISSION PUMP (6K), (2) HYDRAULIC WHEEL MOTORS (4F), H Y D R A U L I C F I LT E R ( 5 K ) , D C L I F T P U M P ( 5 H ) , HYDRAULIC OIL RESERVOIR (5J), SAW LOWER- ING SPEED CONTROL KNOB (1U), and HYDRAULIC LIFT CYLINDER (4G). • HYDRAULIC FILTER (5K) should be changed after the first 50 hours of operation, then every 250 hours of operation. Fill a new HYDRAULIC FILTER (5K) with SAE 10W30 motor oil before installation. • Check HYDRAULIC OIL RESERVOIR (5J) fluid level periodically. Maintain oil level with SAE 10W30 motor oil. DO NOT OVERFILL, check oil level when saw is level.Fill oil to bottom of HYDRAULIC RESERVOIR FILL (5I) port. • Change hydraulic fluid every 500 hours of operation. F i l l H Y D R A U L I C O I L R E S E R V O I R ( 5 I , 5 J ) w i t h approximately 2.5 quarts of SAE 10W30 motor oil. DO NOT OVERFILL! Check oil level when saw is level. Fill oil to bottom of HYDRAULIC RESERVOIR FILL (5I) port. • The lowering rate of the saw can be adjusted using the SAW LOWERING SPEED CONTROL KNOB (1U) at the rear of the saw. If the saw falls too quickly, turn the knob on the SAW LOWERING SPEED CONTROL KNOB (1U) CLOCKWISE until an adequate lowering rate is set. • Replace the Inner Safety Element once per year or if it becomes damaged. • Replace any damaged filters or gaskets. • Check air hose and clamps for damage or looseness. Tighten or replace as required. WHEELS and HUBS: • Check for excess wear and looseness. Tighten or replace as required. FUEL FILTER: • Replace Spin-On Fuel Filter (5F) every 500 hours.
57 14 Engine / Blade Shaft / Gearbox Speed Adjustment (See Figures 1-6) WARNING: Serious injury can occur to the operator or people in the work area if the rotational speed (n/min) of the DIAMOND BLADE (2E) exceeds the maximum speed (n/ min) marked on the DIAMOND BLADE (2E). ENGINE SPEED: The engine speed on this machine does not need to be changed from the factory set speed. The maximum engine RPM should be 3250, no load. BLADE SHAFT SPEED: The blade shaft speed on this machine should be checked before fitting the DIAMOND BLADE (2E) to the machine. Never install a DIAMOND BLADE (2E) if the blade shaft rotational speed (n/min) of the machine is greater than the maximum speed (n/min) marked on the DIAMOND BLADE (2E)! The BLADE SHAFT PULLEY (3-1N, 3-2N) and BLADE SHAFT FLANGE (2B & 2F) may need to be changed if the diameter of the Diamond Blade is changed! SINGLE SPEED GEARBOX MODEL: Each saw model, as delivered from the factory, is designed to operate with a specified range of blade sizes inside the blade guard installed on the machine. If a blade size outside the specified range of sizes for your model must be used, then the saw drive configuration must be changed. If changing from a small to a very large DIAMOND BLADE (2E) on a machine with a single speed gearbox, the Blade Shaft Pulleys (3-1L), Gearbox Pulleys (3-1N), the BLADE SHAFT FLANGES (2B & 2F), and the Blade Guard must be changed. For example, to change a single speed gearbox model from a 14” (350mm) drive to a 36” (900mm) drive: 1. Change Engine Gearbox Pulley from 6.00” (152mm) diameter to 3.50” (88.9mm) diameter. 2. Change Blade Shaft Pulley from 4.12” (114.3mm) diameter to 5.60” (142.2mm) diameter. 3. Change Blade Flanges from 4.50” (114.3mm) diameter to 6” (152mm) diameter. 4. Change BLADE GUARD (2H) from 14” (350mm) to 36” (900mm). 5. Engine Speed does not change. S e e B l a d e S i z e C o n v e r s i o n c h a r t s f o r s p e c i f i c information. THREE SPEED GEARBOX MODEL (14-26, 18-30, 20-36): CAUTION: Never shift the Gearbox (3-2A) with engine running! Only shift the Gearbox (3-2A) with engine OFF! Gearbox damage could occur. See “GEARBOX SHIFT LEVER (3-2O)” for details about operating shift lever. A machine factory equipped with a Three Speed ENGINE GEARBOX (3-2A), while designed to minimize adjustments required for blade size changes, will require some adjustments. The machine is designed to operate with a specified range of blade sizes inside the factory installed blade guard. Color coded information on machine, and information in operation manual, shows allowable blade sizes for current machine drive configuration. There are three (3) machine drive configurations: a) 14-26 for 14” to 26” (350 to 650 mm) blades, b) 18-30, for 18” to 30” (450 to 750 mm) blades, c) 20-36, for 20” to 36” (500 to 900 mm) blades. For example, to change the blade size on a machine drive configuration 18-30 within these range, 18” to 30” (450 to 750 mm), requires only that GEARBOX SHIFT LEVER (3-2O) be moved into the correct position (1, 2, or 3). If the required blade size is outside of the machine drive configuration range [below 18” (450mm) or above 30” (750 mm) for this example], then the machine drive configuration must be changed. This may require shifting the GEARBOX SHIFT LEVER (3-2O), changing BLADE SHAFT PULLEYS (3-2L), GEARBOX PULLEYS (3-2N) and BLADE SHAFT FLANGES (2B & 2F). Example: To change a three-speed gearbox model from a 20” (500mm) drive to a 36” (900mm) drive, first determine the machine drive configuration (14-26, 18-30, or 20-36). This should correspond to the BLADE SHAFT FLANGE (2B & 2F) diameter installed on the saw. If the machine drive configuration is a 20-36, the FLANGE (2B & 2F) diameter is should be 6.00” (152mm): a) Verify proper pulley diameters are installed (See Blade Size Conversion charts for specific information). b) Shift the GEARBOX SHIFT LEVER (3-2O) from 3 to 1. c) Verify that machine drive configuration and blade shaft speed corresponds with information in operation manual, and gearbox range decal (542 19 06-00). If the machine drive configuration is an 18-30, the FLANGE (2B & 2F) diameter should be 5.00” (127mm): a) Change the BLADE SHAFT PULLEY from 4.50” (114.3 mm) diameter to 5.20” (132mm). b) Change the BLADE SHAFT FLANGE from 5.00” (127mm) diameter to 6.00” (152mm). c) Shift the GEARBOX SHIFT LEVER (3-2O) from 2 to 1. d) Verify that machine drive configuration and blade shaft speed corresponds with 20-36 drive configuration information in operation manual. e) Install the 20-36 drive configuration decals (Decals 542 19 06-00, 542 20 65-46, 542 20 65-49 are required). See the “Decals and Locations” page of this manual for more information. If the machine drive configuration is a 14-26, the FLANGE (2B & 2F) diameter should be 4.50” (114.3mm): a) Change the BLADE SHAFT PULLEY from 4.12” (105mm) diameter to 5.20” (132mm). b) Change the BLADE SHAFT FLANGE from 4.50” (114.3mm) diameter to 6.00” (152mm).
58 17 Spare Parts For quick supply of spare parts and to avoid any lost time, it is essential to quote the data on the manufacturers plate fixed to the machine and the part number(s) and description(s) to be replaced with every order. Please reference Parts Lists manual (542 20 10-83): (If you do not have a Parts List Manual, please call TOLL FREE 1-800-288-5040 in USA, or for International, call +1-913-928-1300.) The instructions for use and spare parts found in this document are for information only and are not binding. As part of our product quality improvement policy, we reserve the right to make any and all technical modifications without prior notice. The manufacturer accepts no responsibility caused by unsuitable use or modifications. 16 Repairs We carry out all repairs in the shortest possible time and at the most economical prices. (See back page for our address and phone numbers.) Contact you authorized dealer concerning maintenance and repairs. 15 Accessories BLADE GUARD CONVERSION kITS: Use the proper size blade guard for the particular diamond blade size being operated. The following blade guards are available for these diamond blade sizes: Guard Blade Sizes 36” (900mm) 24” - 36” (600 - 900mm) 30” (750mm) 18” - 30” (450 - 750mm) 26” (600mm) 14” - 26” (350 - 650mm) 18” (450mm) 14” - 18” (350 - 450mm) 14” (350mm) 14” (350mm) See Blade Size Conversion charts for specific information. OPTIONAL KITS: 542 18 11-17* Dual Light Kit c) Change the ENGINE GEARBOX PULLEY from 4.50” (114.3mm) diameter to 4.12” (105mm). d) Shift the GEARBOX SHIFT LEVER (3-2O) from 2 to 1. e) Verify that machine drive configuration and blade shaft speed corresponds with 20-36 drive configuration information in operation manual. f) Install the 20-36 drive configuration decals (Decals 542 19 06-00, 542 20 65-46, 542 20 65-49 are required). See the “Decals and Locations” page of this manual for more information. S e e B l a d e S i z e C o n v e r s i o n c h a r t s f o r s p e c i f i c information. WARNING: Serious injury can occur to the operator or people in the work area if the rotational speed (n/min) of the DIAMOND BLADE (2E) exceeds the maximum speed (n/ min) marked on the DIAMOND BLADE (2E). WARNING: After Shifting Gearbox, lower GEARBOX DETENT kNOB (3-2P) or three- s p e e d E N G I N E G E A R B O X ( 3 - 2 A ) c o u l d be damaged! If gearbox seems hard to shift, a slight movement of the blade shaft may ease movement of GEARBOX SHIFT LEVER (3-2O) into proper gear. Never shift the Gearbox (3-2A) with engine running! Two Neutral positions are available in the Three Speed ENGINE GEARBOX (3-2A). This gearbox can be shifted into neutral if the blade rotation needs to be eliminated while the engine is running. If the machine is equipped with the optional BLADE CLUTCH (1V), the BLADE CLUTCH SWITCH (1V) can be moved to the “0” (OFF) position to eliminate blade rotation while the engine is running.
59 SERVICIO DIARIO: 1. Revise el nivel de aceite del motor. 2. Revise protector de la hora para ver si hay daño. 3. Revise las mangueras y abrazaderas para ver si están dañadas o flojas. Apriete o reemplace según sea necesario. 4. Revise el INDICADOR DE RESTRICCIÓN del filtro de aire. Cambie el filtro de aire primario si el indicador está rojo. 5. Cerciórese de que todos los protectores de seguridad están en su lugar y en buenas condiciones. 6. Drene el agua de la CAJA DE ENGRANAJES DEL MOTOR (3-1ª, 3-2ª) usando la VÁLVULA DE DRENAJE DEL AGUA (3-1C, 3-2C). SERVICIO CADA 50 HORAS: 1. Inspeccione el filtro de aire del radiador y limpie según sea necesario. 2. Compruebe la tensión de la correa trapezoidal de accionamiento de la hoja. Ajuste la tensión de ambos lados uniformemente. ¡NO las apriete en exceso! 3. Lubrique los cojinetes de las ruedas delanteras. 4. Cambie el filtro del sistema hidráulico. (Primeras 50 horas solamente.) SERVICIO CADA 100 HORAS: 1. Cambie el filtro y aceite del motor. 2. Lubrique los cojinetes de pivote del eje delantero. 3. Revise las ruedas para ver si están desgastadas o dañadas. 4. Revise los cubos y las ruedas traseras para ver si están flojos. 5. Revise las abrazaderas de las mangueras del filtro de aire del motor. 6. Revise el nivel de fluido del sistema hidráulico. SERVICIO CADA 250 HORAS: 1. Cambie el filtro del sistema hidráulico. 2. Aplique 2 disparos de grasa a cada extremo del eje de la hoja. SERVICIO CADA 500 HORAS: 1. Cambie el fluido de la caja de engranajes del motor. 2. Cambie el fluido del sistema hidráulico. 3. C a m b i e e l f i l t r o d e c o m b u s t i b l e d e l m o t o r (tipo atornillable) SERVICIO ANUAL: 1. Cambie el elemento primario y de seguridad del filtro de aire. LISTA DE COMPROBACIÓN PRELIMINAR Antes de salir de fábrica, todas las máquinas son probadas exhaust\ ivamente. Siga nuestras instrucciones rigurosamente y su máquina le dará una larga vida ú\ til en condiciones de operación normales Antes de poner en marcha la máquina, asegúrese de leer todas las I\ nstrucciones de operación y familiarícese con el manejo de la máquina. PREPARACIÓN DE LA MÁQUINA: SIEMPRE estacione la máquina en una superficie plana con el motor “AP AGADO” y el interruptor de encendido puesto en la posición “0” (APAGADO) antes de hacer cualquier trabajo de mantenimiento. ¡Deje que la máquina se enfríe! 1. Revise el aceite del motor. Llene hasta la marca “full” en la varilla de medición con aceite clase CE o CD 15W40. 2. Conecte los cables de la batería. LISTA DE COMPROBACIÓN DESPUÉS DE 1 A 2 HORAS DE FUNCIONAMIENTO: SIEMPRE estacione la máquina en una superficie plana con el motor “AP AGADO” y el interruptor de encendido puesto en la posición “0” (APAGADO) antes de hacer cualquier trabajo de mantenimiento. ¡Deje que la máquina se enfríe! 1. Revise las abrazaderas de las mangueras del filtro de aire del motor . Apriételas según sea necesario. 2. Apriete las correas trapezoidales de accionamiento de la hoja. ¡NO las apriete en exceso! REFERENCIA RÁPIDA PARA MANTENIMIENTO PROGRAMADO Antes de hacer cualquier trabajo de mantenimiento, SIEMPRE estacione la máquina en una superficie plana con el motor “APAGADO” y el interruptor de encendido puesto en la posición “0” (APAGADO). ¡Deje que la máquina se enfríe!
60 CAJA DE ENGRANAJES (3-2O) (1, 2 ó 3) y el diámetro máximo de la hoja (pulgadas solamente). La velocidad de rotación (RPM, n/min) de la HOJA DE DIAMANTE (2E) debe permanecer en la banda de color apropiada durante la operación. ADVERTENCIA: ¡Observe la posición d e l I N T E R R U P T O R S E L E C T O R D E L TACÓMETRO (1Z)! El tacómetro puede indicar la velocidad de la hoja o la velocidad del motor. El operador o las personas del área de trabajo pueden sufrir lesiones graves si la velocidad de giro (n/min) de la HOJA DE DIAMANTE (2E) excede la velocidad máxima (n/min) indicada en la HOJA DE DIAMANTE (2E). 1H. INTERRUPTOR DE ARRANQUE DEL MOTOR: Use este interruptor para arrancar y parar el motor. También precalienta el motor cuando se presiona hacia adentro. 1I. MEDIDOR DE VOLTAJE: Indica el voltaje del sistema eléctrico. 1J. I N T E R R U P T O R D E A J U S T E D E L E J E o INTERRUPTOR DIFERENCIAL: INTERRUPTOR DE AJUSTE DEL EJE (Sólo para el modelo de pivote frontal): Mueva el interruptor para ajustar el eje impulsor trasero. Empuje el interruptor hacia la derecha para que la sierra avance hacia la derecha. Hacia la izquierda para que avance hacia la izquierda. INTERRUPTOR DIFERENCIAL (Sólo para el modelo depivote trasero): Tres posiciones para controlar las modalidades de Pivote, Recto o Neutra. Mueva el interruptor a la IZQUIERDA para la modalidad Pivote. Permite que la sierra se pueda pivotar sobre sus ruedas traseras. Mueva el interruptor al CENTRO para la modalidad Recto. Permite que la sierra se mueva en línea recta. Mueva el interruptor a la posición DERECHA (tiene que mantenerse la posisición). El motor de la sierra tiene que estar APAGADO y el INTERRUPTOR DE ARRANQUE DEL MOTOR (1H) en la posición de APAGADO (“0”). Pone la sierra en “Neutro” y permite empujar la máquina. 1K. BOTÓN PULSADOR ROJO: Para PARADA DE EMERGENCIA de la sierra. Su función es interrumpir el suministro de energía a todos los sistemas excepto las luces, TIRE del botón para desenclavarlo. No lo utilice para paradas de rutina. 1L. INTERRUPTOR DE SEGURIDAD DEL AGUA: Apaga el motor si se interrumpe el suministro d e a g u a a l a h o j a . A j ú s t e l o p a r a a c t i v a r el interruptor. 1M. INTERRUPTOR DEL TOPE DE PROFUNDIDAD DE LA HOJA: Activa o anula el tope de velocidad para cortes repetitivos a la misma profundidad. 1N. INDICADOR DE RESTRICCIÓN DE AIRE: Limpiar los elementos del filtro de aire cuando el indicador muestra una marca roja. Reactívelo antes de arrancar el motor. FIGURA 1: 1A. PERILLA: Utilícela para apretar las empuñadura de los manillares. (Igual que 6G) 1B. MANILLARES: Para que el operador se sujete. NO se debe usar para levantar la sierra. (Igual que en 6G) 1C. H O R Ó M E T R O : R e g i s t r a l a s h o r a s d e funcionamiento del motor. 1D. ---- 1E. TERMÓMETRO DEL AGUA: El refrigerante es agua/glicol. Monitorea la temperatura del refrigerante del motor. La temperatura máxima segura es 220°F (104.4°C). 1F. A C E L E R A D O R D E L M O T O R : C o n t r o l a l a velocidad (rpm) del motor. Oprima el botón rojo para desbloquear. Empuje hacia dentro para disminuir la velocidad (rpm). Tire del botón para aumentar la velocidad (rpm). O, gírelo en sentido horario para aumentar la velocidad (rpm). Gírelo en sentido contrahorario para disminuir la velocidad (rpm). 1G. TACÓMETRO: Muestra la velocidad del motor (RPM, n/min) o la velocidad del eje de la hoja (RPM, n/min) si está equipado con el INTERRUPTOR SELECTOR DEL TACÓMETRO (1Z), ya que de lo contrario muestra solamente la velocidad del motor (RPM, n/min). Seleccione la pantalla del TACÓMETRO moviendo el INTERRUPTOR SELECTOR DEL TACÓMETRO (1Z) a la posición deseada (si lo tiene). Los modelos de caja de engranajes de tres velocidades tienen bandas de color (verde, amarilla y anaranjada), mostradas alrededor del exterior del tacómetro, que relacionan la posición de la PALANCA DE CAMBIOS DE LA