CS8 Series Random Crack Saw Operator Manual- Brochure

OPERATOR MANUALIncludes Safety, Service and Replacement Part Information Model CS8Random Crack SawForm: GOM5229601Version 1.2Do not discard this manual. Before operation, read andcomprehend its contents. Keep it readily available for referenceduring operation or when performing any service relatedfunction. When ordering replacement parts, please supply thefollowing information: model number, serial number and partnumber. For customer service assistance, telephone800.533.0524, +507.451.5510. Our Customer Service Departmenttelefax number is 877.344.4375 (DIGGER 5), +507.451.5511.There is no charge for customer service activities .Internet address: http://www.generalequip.com.E-Mail location: general@generalequip.com.Copyright 2003, General Equipment Company.Manufacturers of light construction equipment620 Alexander Drive SW • P.O.?Box 334 • Owatonna, Minnesota 55060-0334 USATelephone: 800.533.0524 • International Telephone: +507.451.5510Telefax: +507.451.5511 • Sales/Customer Service Department Toll Free: 877.344.4375 (DIGGER 5)http://www.generalequip.com • e-mail: general@generalequip.com Congratulations on your decision to purchase a General light construction product. From ourhumble beginnings in 1955, it has been a continuing objective of General Equipment Company tomanufacture equipment that delivers uncompromising value, service life and investment return.Because of this continuous commitment for excellence, many products bearing the General nameactually set the standards by which competitive products are judged.When you purchased this product, you also gained access to a team of dedicated andknowledgeable support personnel that stand willing and ready to provide field supportassistance. Our team of sales representatives and inhouse factory personnel are available toensure that each General product delivers the intended performance, value and investment return.Our personnel can readily answer your concerns or questions regarding proper applications,service requirements and warranty related problems.General Equipment Company places great emphasis upon not only product performance, but alsoon product safety. It is important to remember that this product will only be as safe as the operatorswhich utilize it. It just makes good, common sense to take the time to read and fully understand thecontents of this manual before attempting to utilize this product in service. If you ever do have anyquestions or concerns about this product, please feel free to contact our Customer ServiceDepartment at the telephone numbers listed below for assistance.If there is anything that I can do to assist your efforts when utilizing this product, please do nothesitate to contact me. For assistance after normal business hours, telephone me at 507.451.9409or 507.363.1033. If I am not immediately available, I will attempt to return your call as soon aspossible.Sincerely,GENERAL EQUIPMENT COMPANYDennis Von RudenPresidentCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 2DESCRIPTION PAGENotice to OperatorOperational Instructional Data SheetSafety PrecautionsPREPARATION.OPERATION.MAINTENANCE, REPAIR AND STORAGE.AssemblyREMOVING ThE CRACK SAW FROM ThE PALLET.Before Starting the EngineFILLING ThE ENGINE CRANKCASE WITh OIL.FILLING ThE CS8/G SERIES ENGINE FUEL TANK.FILLING ThE CS8/GhP PROPANE CyLINDER.OperationThEORy OF OPERATION.INFORMATION RELATIVE TO ThE USE OF DIAMOND BLADES.INSTALLING A DIAMOND BLADE ON ThE ARBOR ShAFT.TRANSPORTING ThE CRACK SAW.STARTING ThE CS8/E SERIES ELECTRICALLy POWERED CRACK SAWON ThE JOB SITE.STARTING ThE CS8/G SERIES GASOLINE POWERED CRACK SAW ONThE JOB SITE.PROCEDURES FOR ThE SAFE hANDLING OF PROPANE.ExAMPLE OF A PROPANE EMERGENCy PLAN.STARTING ThE CS8/GhP SERIES PROPANE CONVERTED SAW ON ThEJOB SITE.COUNTERACTING ThE PROPANE REFRIGERATION EFFECT.OPERATING ThE CRACK SAW ON ThE JOB SITE.STOPPING ThE CS8/E SERIES ELECTRICALLy POWERED CRACK SAW.STOPPING ThE CS8/G SERIES GASOLINE POWERED CRACK SAW.STOPPING ThE CS8/GhP PROPANE CONVERTED CRACK SAW.OPERATIONAL PARAMETERS AND TEChNIq UES FOR ThE CS8 SERIESCRACK SAW.457791011111111121213131315182022242425272836363636Table of ContentsCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 3CS8 RANDOM CRACK SAW, FORM GOM5229601, VERSION 1.1, AUTHORIZATION: DVR, PAGE: 3DESCRIPTION PAGEServicePREVENTATIVE MAINTENANCE ChECK LIST.ChECKING V-BELT TENSION AND ALIGNMENT.INSTALLING A REPLACEMENT V-BELT OR PULLEy.INSTALLING REPLACEMENT BEARINGS ON ThE ARBOR ShAFT.LUBRICATION REq UIREMENTS.ELECTRIC MOTOR SERVICE.ENGINE SERVICE.TroubleshootingELECTRIC MOTOR.ENGINE.OPERATIONAL PROBLEMS.StorageSpecificationsReplacement Parts Diagrams383840414146464647474748515153CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 4Notice to OperatorsIF yOU CAN NOT READ OR DO NOT FULLy UNDERSTAND ThE CONTENTS OF Th ISMANUAL, PLEASE CONTACT ThE FACTORy FOR PROPER ASSISTANCE BEFOREATTEMPTING TO OPERATE Th IS PRODUCT.SI TU NO PUEDES LE'ER O NO COMPRENDES EL CONTENIDO DE ESTE MANUALFAVOR DE PONERSE EN CONTACTO CON LA. FABRICA PARA ASSISTENCIA- APROPIA ANTES DE INTENTAR PARA OPERAR ESTE PRODUCTO.SOLLTEN SIE DIESE GEBRAUChSANWEISUNG NIChT LESEN KOENNEN ODER ESNICh T VOLLKOMMEN VERSTEh EN, WENDEN SIE SICh BITTE AN DENhERSTELLER FUER RIChTIGE h ILFE EhE SIE VERSUChEN DIESES PRODUKT ZUOPERIEREN.SI VOUS NE LISEZ OU NE COMPRENDRE ENTIEREMENT LES MATIERES DE CEMANUEL, S'IL VOUS PLAIT, CONTACTEZ L'USINE POUR L'ASSISTANCEAPPROPRIEE AVANT D'UTILISER LE PRODUIT.These safety alert symbols identify important safety messages in this manual. When you see thesesymbols, be alert to the possibility of personal injury and carefully read the message that follows.Do not allow anyone to operate the Crack Saw without first reading this Operator's Manual andbecoming familiar with its operation. The manufacturer of this Crack Saw has gone to great extremesto provide the owner(s) and/or operator(s) with the finest equipment available for its intended jobfunction of sawing random crack patterns on horizontal floor surfaces. yet, the possibility exists thatthe Crack Saw can be utilized in and/or subjected to job applications not perceived and/oranticipated by the manufacturer. Such misuse and/or misapplication of the Crack Saw can lead tothe possibility of serious damage, injury or even death. It is the responsibility of the owner(s) and/oroperator(s) to determine that the Crack Saw is being utilized and/or operated within the scope of itsintended job function. It is the responsibility of the owner(s) and/or operator(s) to establish, monitorand constantly upgrade all safety programs and/or practices utilized in and for the operation of theCrack Saw. The purpose of such programs is to provide for owner(s') and/or operator(s') safety.Operators must be instructed to recognize and avoid unsafe conditions associated with their work(29 CFR 1926.21 (b)(2)) and/or applicable updated revisions. It is the responsibility of the owner(s)and/or operator(s) to determine that no modifications and/or alterations have been made to theCrack Saw. Modifications and/or alterations can lead to the possibility of serious damage, injury oreven death. It is the responsibility of the owner(s) and/or operator(s) to make this Operator's Manualavailable for consultation during all phases of operation. Refer to OShA 2207 and/or applicableupdated revisions which contains all OShA job safety and health rules and regulations (1926 and1910) covering construction.The concept of frame mounted type Crack Saws has been successfully utilized for many years as apractical solution to many types of random crack sawing requirements. The basic concept is provenCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 5and well accepted within the associated marketplaces. Use of a Crack Saw requires strenuous workactivity. This type of work activity can be considered to be greater in magnitude than thatexperienced with the use of many other types of both light construction and lawn and garden relatedequipment. This type of work activity should only be attempted by operators of adequate physicalsize and stature, mental awareness and physical strength and condition. The body parts mostnoticeably affected during the planing process are the arms, hands, wrists, shoulders, lower backand legs. The process can also produce excessive stress/strain directly to the back muscles, spinalvertebrae and many other body parts. Back related pain can be a side effect of utilizing a Crack Saw.An operator with a chronic back related problem or a history of back and/or other medically relatedproblems should not attempt to utilize the Crack Saw. Use of the Crack Saw may only aggravate thisand any other medically related problem. Because of the diverse type of prevailing job applications,job site conditions, operator experience levels and operator physical characteristics, no warranty,guarantee, representation and/or liability is made by the manufacturer as to the absolute correctnessor sufficiency of any operational procedure, operational position and/or technique. There is noabsolute guarantee that an operator of any given experience level, physical size and/or physicalcondition will be immune to the possibility of and/or probable physical side effects of the normal useof the Crack Saw. Each potential operator must be made aware of and assume the operational andphysical liability described and/or associated with the use of the Crack Saw. Improper use of theCrack Saw can result in property damage and/or personal injury, including death. Each potentialoperator not willing to assume the operational and physical liability described and/or associatedwith the use of the Crack Saw, should not operate it. Proper levels of operator experience, skill andcommon sense are essential for maximizing the safe and efficient operation of the Crack Saw.Record the Crack Saw and engine/electric motor serial numbers in the spaces provided below._______________ Model Number_______________ Serial Number_______________ Engine/Electric Motor Serial Number_______________ Date of PurchaseSpecifications and design are subject to change without notice or obligation. All specifications aregeneral in nature and are not intended for specific application purposes. General EquipmentCompany reserves the right to make changes in design, engineering or specifications and to addimprovements or discontinue manufacture at any time without notice or obligation. GeneralEquipment Company and its agents accept no responsibility for variations which maybe evident inactual products, specifications, pictures and descriptions contained in this publication.Operator Instructional Data SheetThe following undersigned operators of the Crack Saw described and/or pertaining to this Operator'sManual have received formal safety and operational information/instruction from the undersignedowner(s)/instructor(s) in accordance to OShA 29 CFR 1926.21 (b)(2) and/or applicable updatedrevisions pertaining to, but not necessarily limited to the:CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 61) READING, COMPREhENSION AND ACKNOWLEDGEMENT OF ThE MATERIAL COMPRISING ThEENTIRE CONTENTS OF ThE APPLICABLE OPERATOR'S MANUAL AND SAFETy AND OPERATIONALINFORMATION VIDEO TAPE FOR ThE CRACK SAW.2) FORMALIZED OPERATOR'S SAFETy PROGRAM TO BE DEVISED By ThE OWNER OF ThE CRACKSAW IN CONJUNCTION WITh ThE CONTENTS OF ThE APPLICABLE OPERATOR'S MANUAL,SAFETy AND OPERATIONAL INFORMATION VIDEO TAPE FOR Th E CRACK SAW AND Th EAPPLICABLE MATERIAL INCLUDED IN ThE NATIONAL ELECTRIC CODE®.3) OShA AND NATIONAL ELECTRIC CODE® RULES AND REGULATIONS RESEARChED FORAND/OR By ThE OWNER OF ThE CRACK SAW AND DEEMED APPLICABLE TO ThE SAFE ANDPROPER USE AND/OR OPERATION OF ThE CRACK SAW FOR ANy SPECIFIC JOB APPLICATION.4) LOCAL LAWS, REGULATIONS AND CUSTOMS RESEARChED FOR AND/OR By ThE OWNER OFTh E CRACK SAW AND DEEMED APPLICABLE TO Th E SAFE AND PROPER USE AND/OROPERATION OF ThE CRACK SAW FOR ANy SPECIFIC JOB APPLICATION.5) FORMALIZED MAINTENANCE PROGRAM FOR ThE CRACK SAW TO BE DEVISED By ThE OWNEROF Th E CRACK SAW IN ACCORDANCE WITh , BUT NOT NECESSARILy LIMITED TO, Th ESPECIFICATIONS, GUIDELINES AND OPERATIONAL INFORMATION CONTAINED IN Th EAPPLICABLE OPERATOR'S MANUAL. 6) COMPREhENSIVE OPERATIONAL INSTRUCTIONS FOR ThE CORRECT AND PROPER USE OFThE CRACK SAW AS PER ThE CONTENTS OF ThE APPLICABLE OPERATOR'S MANUAL, SAFETyAND OPERATIONAL INFORMATION VIDEO TAPE AND APPLICABLE MATERIAL INCLUDED IN ThENATIONAL ELECTRIC CODE®._______________ Operator _______________ Owner/Instructor __________ Date_______________ Operator _______________ Owner/Instructor __________ Date_______________ Operator _______________ Owner/Instructor __________ Date_______________ Operator _______________ Owner/Instructor __________ Date_______________ Operator _______________ Owner/Instructor __________ Date_______________ Operator _______________ Owner/Instructor __________ DateNOTE: INSERT COPIES OF Th IS PAGE WITh IN ThE OPERATOR'S MANUAL IF SPACE FORADDITIONAL OPERATORS IS REq UIRED. Safety PrecautionsThE FOLLOWING SAFETy PRECAUTIONSPROVIDE SOME COMMON SENSE GUIDES TOPROMOTE SAFETy AND EFFICIENCy WITh ThECRACK SAW. NO WARRANTy, GUARANTEE ORREPRESENTATION IS MADE By ThEMANUFACTURER AS TO ThE ABSOLUTECORRECTNESS OR SUFFICIENCy OF ANyINFORMATION OR STATEMENT. ThESE SAFETyPRECAUTIONS ARE INTENDED TO DEALPRINCIPALLy WITh COMMON PRACTICES ANDCONDITIONS ENCOUNTERED IN ThE USE OF ThECRACK SAW AND ARE NOT INTENDED TO BE ALLINCLUSIVE. PROPER LEVELS OF OPERATORExPERIENCE, SKILL AND COMMON SENSE AREESSENTIAL FOR SAFE AND EFFICIENTOPERATION.ThE ENGINE ExhAUST FROM ThIS PRODUCTCONTAINS ChEMICALS KNOWN TO ThE STATEOF CALIFORNIA TO CAUSE CANCER, BIRThDEFECTS OR OThER REPRODUCTIVE hARM.ThIS STATEMENT IS MADE IN COMPLIANCE TOCALIFORNIA PROPOSITION 65.INCORRECT USE OF ThE CRACK SAW CANRESULT IN PROPERTy DAMAGE, PERSONALINJURy OR EVEN DEATh. TO REDUCE Th ISPOSSIBILITy, GIVE COMPLETE AND UNDIVIDEDATTENTION TO ThE JOB AT hAND AND FOLLOWThESE SAFETy PRECAUTIONS:PREPARATION.1) This Crack Saw is a specialized type of poweredequipment, designed for a specific job function andrequires adequate and thorough instruction BEFORE itis operated. The size, power, complexity and operatingcharacteristics of this type of powered equipmentwould dictate that each operator must receiveadequate, professional instruction regarding the properoperation of this Crack Saw before being allowed toutilize it. BEFORE attempting to utilize this Crack Saw,read this Operator's Manual, the applicable Safety andOperational Information Video Tape and the materialsupplied by the engine manufacturer to familiarizeeach operator with its correct operating procedures.Avoid the urge not to take the necessary time to readthis Operator's Manual before operating the CrackSaw. DO NOT OPERATE THE CRACK SAW UNTILEACH OPERATOR COMPLETELY COMPREHENDSTHE CONTENTS OF THIS MANUAL AND THEAPPLICABLE SAFETY AND OPERATIONALINFORMATION VIDEO TAPE.2) Develop a comprehensive program for the safeoperation of the Crack Saw by its owner(s) and/oroperator(s). Such a program will include, but is notlimited to: instructional requirements for operation,applicable OSHA requirements, local laws andregulations, job site safety and a Crack Sawmaintenance program. Constantly examine andupgrade this program to guarantee owner(s) and/oroperator(s) safety. Each operator must be fullyinstructed regarding the specifics of this safetyprogram. 3) Determine that the Crack Saw is in its original,factory configuration and has not been modified in anymanner. Many modifications can result in potentiallydangerous configurations that can lead to propertydamage and/or personal injury. If there are anyquestions about possible modifications made to theCrack Saw, contact the Customer Service Departmentfor specific information BEFORE utilization. There is nocharge for this service. Do not operate the Crack Sawwithout the use of the original equipment V-belt anddiamond blade guards. Use of the Crack Saw withoutan approved belt guard and/or diamond blade guardcan lead to property damage and/or personal injury.4) Minors should never be allowed to operate theCrack Saw. Bystanders, especially children andanimals, should not be allowed in the area where theCrack Saw is in use. The sawing process can result inflying particles being emitted at high velocity andstriking the operator and/or onlookers. This can lead tothe possibility of property damage and/or personalinjury. Keep all body parts, loose clothing, foreignobjects and onlookers clear of the rotating diamondCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 7blade, caster wheels, main wheels and flying particles.5) Operators must be in adequate physical condition,mental health and not under the influence of anysubstance (drugs, alcohol, etc.) which might impairvision, dexterity or judgment. Working with the CrackSaw is strenuous. If you have any condition that mightbe aggravated by strenuous work, check with yourdoctor BEFORE operating the Crack Saw. Guardagainst the possibility of back related injuries. Alwayslift the Crack Saw with leg muscles and not with theback.6) Prolonged use of the Crack Saw (or other, similarmachines) exposes the operator to vibrations whichmay produce Whitefinger Disease (Raynaud'sPhenomenon). This phenomenon reduces the hand'sability to feel and regulate temperature, producesnumbness and burning sensations and may causenerve and circulation damage and tissue necrosis.Antivibration systems do not guarantee that you will notsustain Whitefinger Disease. Therefore, continuousand regular users should closely monitor the conditionof their hands and fingers. After each period of use,exercise to restore normal blood circulation. If any ofthe symptoms appear, seek medical adviceimmediately.7) Clothing must be sturdy and snug fitting, but allowcomplete freedom of movement. Never wear loosefitting jackets, scarves, neckties, jewelry, flared orcuffed pants or anything that could become caught oncontrols or moving parts. Wear long pants to protectyour legs. Protect your hands with heavy duty, nonslipgloves to improve your grip. Good footing is mostimportant when operating the Crack Saw. Wear sturdyboots with nonslip soles. Steel-toed safety shoes arehighly recommended. Never wear tennis shoes orother, similar type shoes which afford little or noprotection. Wear an approved safety hard hat toprotect the operator'(s') head(s) where there is adanger of head injuries. Noise, generated by theengine of the Crack Saw and the actual process itself,can damage your hearing. Wear approved soundbarriers (ear plugs or ear mufflers) to protect yourhearing. Continuous and regular operators shouldhave their hearing checked regularly.8) Visually inspect the Crack Saw, components, toolsand accessories for damaged or worn parts. BEFOREeach use:a) Disconnect the engine spark plug wire or powersource cable.b) Clean and remove all accumulated foreign matterfrom the wheels and determine that each rotates freely.c) Clean and remove all accumulated foreign matterfrom inside the main frame area.d) Inspect the V-belt drive for proper tension, wear andgeneral condition. Replace each component asnecessary.e) Inspect the arbor shaft and diamond blade guardassemblies for excessive wear and structural integrity.Replace each component as necessary. The arborshaft rotates at high speed during the specific processand can be subject to high wear rates if the installeddiamond blade is not properly maintained and/orreplaced at regular service intervals.f) Determine that operator controls work freely, allsafety devices are operative and information decalsare readable. g) Check to see that the Crack Saw and all relatedaccessories are in good, mechanical conditionBEFORE utilization.h) Reconnect the spark plug wire or power sourcecable as applicable.9) Contact appropriate representatives to determineif/where electrical cables, gas lines and otherhazardous items are buried under the work surfaceBEFORE utilization. The Crack Saw and relatedaccessories are not insulated. Contact with buriedelectrical cables, gas lines and other hazardous itemscan result in electrocution and/or an explosion.10) Know how the controls operate. Know how to stopthe engine or electrical motor quickly in an emergency.Always start the engine or electric motor according tothe instructions as outlined in this manual to minimizethe possibility of unexpected contact with the worksurface. Unexpected contact with the work surface cancause loss of machine control, and the possibility ofproperty damage and/or personal injury.11) Ground the CS8/E electrically powered Crack Sawmotor securely. Determine that any "grounding" wireand/or device is, in fact, properly grounding the motor.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 8Failure to properly ground the motor may cause anelectrical shock and/or electrocution, resulting inproperty damage and personal injury, including death.Electrical wiring and all connections should beperformed by a qualified electrician. Determine that theelectric motor is being operated on the correct voltageaccording to the intended and/or available powersource. Operating the electric motor from an impropervoltage/amperage power source can result in propertydamage and/or personal injury. 12) Never exceed the recommended capacities of theCrack Saw. Refer to the Specifications section of thismanual for more detailed information.OPERATION.1) Give complete and undivided attention to the job athand. Do not chew gum, smoke and/or use smokelesstobacco while utilizing the Crack Saw. Do not attemptto eat and/or drink while utilizing the Crack Saw.Determine that eyeglasses and/or hearing aid devicesare properly secured.Use of the Crack Saw is strenuous and causes fatigue.Help prevent the cause of an accident. Plan to takework breaks as required to help maintain proper mentaland physical alertness.2) This Crack Saw is not sealed or insulated. Do notoperate this machine in an explosive atmosphere ornear combustible materials. Refer to current OSHAand National Electric Code® rules and regulations.3) Gasoline is an extremely flammable fuel. Useextreme caution when handling gasoline or mixing fuel.Always utilize UL®, CSA® OR CE approved containersfor the storage and transportation of fuel. Do not smokeor bring fire or flame near the fuel. Always shut off theengine and allow it to cool before refueling. Neverremove the fuel tank filler cap while the engine isrunning. Never operate an engine without a fuel tankfiller cap. Select bare ground for fueling and move atleast 10 feet from the fueling spot before starting theengine. Wipe off any spilled fuel before starting theengine and check for leakage. If a fuel or oil leak isfound, do not start or run the engine until the leak isfixed and the spillage has been wiped away. Take carenot to get fuel or oil on your clothing. If this happens,change your clothing immediately. Before operating theCrack Saw refer to the Specifications section of thismanual for more detailed information regarding fueland lubrication requirements.4) The Crack Saw is designed for use by one operator.Use of the Crack Saw by more than one operator canlead to confusion and loss of control, resulting inproperty damage and/or personal injury. If it is felt thatmore than one person is required to operate the CrackSaw, STOP and contact the Customer ServiceDepartment for specific operational andservice/maintenance information. There is no chargefor this service.5) Do not operate the Crack Saw with onlookers closeby. Caution all onlookers to stand clear. The sawingprocess can result in flying particles being emitted athigh velocity and striking the operator and/oronlookers. This can lead to the possibility of propertydamage and/or personal injury. Keep all body parts,loose clothing and foreign objects clear of the rotatingdiamond blade. 6) Start the engine or electric motor according to theinstructions as outlined in this manual to minimize thepossibility of unexpected contact with the work surface.Unexpected contact with the work surface can causethe loss of machine control and the possibility ofproperty damage and/or personal injury.7) Start and operate the Crack Saw only in a wellventilated area. Carbon Monoxide fumes given off byan engine are poisonous. Breathing these fumes canresult in property damage and/or personal injury.Operate the Crack Saw only when/where visibility andlight are adequate for the job at hand. Work carefully.Always hold the operator handle firmly with bothhands. Wrap your fingers around the handle, keeping itcradled between your thumbs and fingers. Alwaysmake sure the operator handle is in good condition andfree of moisture, pitch, oil or grease. Wear gloves toimprove your grip. Never leave the Crack Saw runningunattended.8) Special care must be exercised on slipperyconditions and on difficult, uneven surfaces. Watch forcracks, high spots and other, surface irregularities.Keep proper footing and balance at all times. Thenormal use of this machine is on level surfaces. Otherterrains can be dangerous and should be avoided.Only properly trained operators should attempt thesetechniques.9) Never start the engine or electric motor with theCrack Saw directly over cracked, uneven or irregularCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 9surfaces. Start the engine or electric motor accordingto the instructions as outlined in this manual. 10) Contact with a hot, engine muffler can causeproperty damage and/or personal injury. Remain clearof a hot, engine muffler. Do not over speed the engineby altering the governor setting or by disconnecting theengine governor. Serious damage to the engine and/orpersonal injury can result.11) Clean and remove all accumulated foreign matterfrom inside the main frame area after each use. Thispractice will maximize bearing and V-belt service life.12) Because this Crack Saw is classified as a low cost,hand held, low horsepower, portable type machine, it islimited in the number of practical and/or suitable jobapplications. A particular job site, actual surfaceconditions, job specifications and operatorskill/common sense may dictate that a different type ofmachine (with characteristics of higher purchase cost,being mounted to a carrier vehicle, with greaterhorsepower and less mobility), method and/or processbe utilized to properly complete the job with the degreeof efficiency and safety required. Contact the CustomerService Department for specific information regardingsuitable job applications, job sites surface conditionsand operator experience/skill/common senserecommendations for this Crack Saw BEFOREutilization. There is no charge for this service.MAINTENANCE, REPAIR AND STORAGE.1) Use only genuine, approved replacement parts andaccessories for maintenance and repair. Use of partsand accessories manufactured by others can result inproperty damage and/or personal injury.2) Follow the Service instructions as outlined in theappropriate section of this manual.3) Always stop the engine or electric motor anddisconnect the spark plug wire or power source cableBEFORE checking or working on the Crack Saw.4) Always properly maintain the Crack Saw. Frequentlycheck all fasteners and individual parts. Built in safetyfeatures are effective only if they are maintained ingood working condition. Replace any questionable partor assembly with a genuine, factory approved,replacement part. Do not forsake proper maintenancefor the price of a few replacement parts. Propermaintenance does not cost...it actually pays dividends.Do not attempt any maintenance repair work notdescribed in this manual. Have such work performed atyour dealer's service facility.5) A worn or damaged engine muffler is a fire hazardand may cause loss of hearing. Check to see that themuffler is in good condition. If the muffler is equippedwith a spark arresting device, determine that it is inproper working condition at regular service intervals.Replace the spark arresting device with an approvedreplacement if there is any question of its integrity. It isthe responsibility of the owner(s) and/or operator(s) toprovide for and properly maintain a USDA approved,spark arresting muffler in an operating area specifiedby law. Check with appropriate governing agencies formore specific information. The Crack Saw must not beoperated if the muffler is faulty or has been removed.Contact with a hot engine muffler can cause propertydamage and/or personal injury.6) Do not operate the Crack Saw without the use offactory approved V-belt and diamond blade guards thatare maintained in proper structural condition.Frequently inspect the guards for signs of wear, cracksand other signs of fatigue. If there is any questionregarding the structural integrity and/or condition of thebelt guard, properly dispose and replace with agenuine, factory approved, replacement part only.7) Maintain all safety and operation decals in propercondition. If any decal becomes damaged and/orunreadable, replace with a genuine, factory approved,replacement part only.8) The Crack Saw utilizes many self locking typehexagon head nuts to minimize the effects of vibration.Replace all self locking hardware with genuine, factoryapproved, replacement parts only. 9) Consult the material supplied by the engine orelectric motor manufacturer for specific informationrelative to proper operational, lubrication and storagerequirements.10) Properly maintain the Propane conversioncomponents for the CS8/GHP Crack Saw. Keepforeign objects from inflicting direct contact blows withthe conversion components located next to the engine.Have only American Gas Association (AGA) and/orCanadian Gas Association (CGA) certified techniciansperform any necessary service work on the PropaneCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 10conversion components. Properly utilize, service andstore Propane cylinders according to establishedAmerican Gas Association (AGA) and/or CanadianGas Association (CGA) recommended practices.Failure to properly utilize, service and store Propanecylinders can result in property damage and/orpersonal injury.AssemblyThe CS8 Series Crack Saw is shipped from the factorysecured on a specially designed wooden pallet andprotected from external damage by a corrugatedcarton or wood crate. If shipped with a corrugatedcarton, the Crack Saw can be secured to the pallet bywood laths nailed to the pallet body. Remove thecarton or crate immediately upon receipt using suitabletools to remove the nails.REMOVING ThE CRACK SAW FROM ThE PALLET.Application: All ModelsTools Required:1 each, pliers.1 each, claw hammer or a hammer and an appropriatepry bar.The Crack Saw is secured to the pallet with steelbanding. Using the pliers, cut and remove the banding.The Crack Saw can then be removed from the pallet.WEAR SAFETy GLASSES AND OThERAPPROPRIATE SAFETy APPAREL WhENCUTTING ThE STEEL BANDING AND/ORREMOVING ThE CORRUGATED/WOOD ShIPPINGCRATE.Visually inspect the shipment for freight damage and/ormissing parts. If shipping damage is evident, contactthe delivering carrier immediately to arrange for aninspection of the damage by their claimsrepresentative. Federal law requires that a claim befiled within a specific time period. If missing parts aredetected, notify your dealer who will assist you inobtaining them.The Crack Saw is shipped from the factory completelyassembled. If ordered with the Crack Saw,attachments or accessories are normally shippedseparately to minimize the potential for loss duringshipment.Check all fasteners for proper security. Consult afastener torque chart for the proper torque value if anyfastener is found to require retorquing.Before Starting the EngineFILLING ThE ENGINE CRANKCASE WITh OIL.Applications: CS8/G Series and CS8/Gh PCrack SawNote: The CS8/GHP Crack Saw is shipped with oil inthe engine crankcase and with the Propane tankempty. Units are test run to insure that the Propaneconversion components are functioning properly.Regular gasoline powered units are selected atrandom at the factory and also test run. These units areshipped with oil in the engine crankcase. Fuel isdrained from the fuel tank and will be markedaccordingly by factory personnel.Tools Required:1 each, small, clean funnel.The CS8/G Series Crack Saw is available equippedwith a variety of industrial quality, electric motors alongwith gasoline and diesel engines. Engines are notnormally preserviced at the factory (see note above)and will require the addition of oil in the crankcasebefore being placed in service. Consult the materialsupplied by the engine manufacturer for the enginethat has been ordered with your Crack Saw. Carefullyreview this material to become familiar with specificoperating characteristics, recommendations andservice requirements.1) Determine the location(s) of both the oil filler and oildrain plug(s).2) Wipe oil, dust and accumulated dirt from the fillerplug area.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 113) Using the funnel, fill the engine crankcase with ahigh grade motor oil. Consult the material supplied bythe engine manufacturer for proper amount, weightand service classification.4) Replace the oil filler plug and tighten. Wipe off anyexcess oil spilled on the engine crankcase and CrackSaw.5) Do not operate the engine unless proper oil level ismaintained as per the material supplied by the enginemanufacturer.FILLING ThE CS8/G SERIES ENGINE FUEL TANK.Tools Required: 1 each, small, clean funnel.Never mix oil with gasoline. Four cycle engines arenot designed to be operated with oil mixed with thegasoline.1) Determine the location of the fuel tank filler cap.2) Carefully clean the filler cap and surrounding area toinsure that no dirt or debris falls into the fuel tank.Remove the filler cap.3) Using the funnel, fill the fuel tank with fresh, cleanfuel according to the specifications outlined in thematerial supplied by the engine manufacturer. Do notoverfill the tank or spill any fuel. If the fuel tankincorporates a screen mesh to prevent debris fromfalling into the tank, do not remove to increase the fillrate. Replace the filler cap. Wipe away any excessspilled fuel.MANy FUELS ARE ExTREMELy FLAMMABLE. DONOT SMOKE NEAR ThE FUEL TANK. DO NOT FILLThE FUEL TANK WITh ThE ENGINE RUNNING ORIF IT IS hOT. ALLOW AMPLE TIME BETWEENEACh REFUELING FOR ThE ENGINE TO COOL.FILLING ThE CS8/GhP PROPANE CyLINDER.The CS8/GHP Crack Saw is shipped from the factorywith a Propane conversion kit for the Honda GX340engine and supplied with a standard 14 lb capacityPropane cylinder. The Propane conversion isperformed by knowledgeable personnel licensedand/or certified to perform the conversion. A copy of theoriginal licensing certificate is shipped with eachmachine. If the original certificate becomes destroyedor lost, contact the Customer Service Department for aduplicate. There is no charge for this service.Empty Propane cylinders should always be filledaccording to established, industry standards byqualified personnel. Cylinders should be tested forstructural integrity according to industry standardsand/or local code requirements by qualified personnelonly.IMPROPER USE, hANDLING AND MAINTENANCEOF ThE PROPANE CyLINDER CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.INSPECT ThE CyLINDER, VALVE, FITTINGS,hOSES AND hARDWARE FOR DAMAGE BEFOREAND AFTER EACh USE. REPLACE ANyq UESTIONABLE COMPONENT WITh A FACTORyAPPROVED REPLACEMENT ONLy. DO NOTALLOW ANy PERSONNEL TO OPERATE APROPANE CONVERTED ENGINE UNTIL PROPERAND/OR ADEq UATE INSTRUCTION hAS BEENGIVEN WITh FULL COMPREhENSION.PROPANE IS AN ExPLOSIVE GAS. DO NOTSMOKE OR INTRODUCE AN OPEN FLAME IN ORNEAR ThE PROPANE CyLINDER AT ANy TIMEWhEN FILLING, OPERATING/UTILIZING ThECRACK SAW OR PERFORMING ANyMAINTENANCE.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 12OperationThEORy OF OPERATION.Application: All ModelsThe CS8 Series Crack Saw operates on the principleof transmitting horsepower through a V-Belttransmission directly to an industry standard, 8 inchdiameter, diamond segment blade of various widths. The crack sawing process is directly controlled bythese conditions:a) The use of a suitable mechanism (diamond blade) ofproper design and configuration to penetrate the worksurface and remove material while deliveringacceptable service life.b) Sufficient static weight supporting the diamondblade to allow it to effectively penetrate the worksurface and remove material.c) Adequate horsepower capable of rotating thediamond blade at industry recognized speeds againstthe work surface to deliver acceptable productivityrates.Since no two materials are exactly alike, no two worksurface materials can be sawed by the exact samemethod. The nature of the sawing process, along withoperator experience, skill and common sense, wouldsuggest that efficient and productive crack sawing is amatter of trial and error. Combinations of diamondblade type, condition, and feed rate are direct factorsthat will also determine the overall success of the jobapplication.INFORMATION RELATIVE TO ThE USE OFDIAMOND BLADES.Application: All Models..."safety requirements always override performanceconsiderations. Diamond blade technology has madesuch rapid advances during the past few years that adiamond blade, properly used, on well designed andwell maintained equipment, can provide the lowestcost per cut of any of the methods of cutting now inuse. But, put that same blade onto a piece of poorlymaintained equipment and in the hands of a poorlytrained operator and the cost of cutting can virtually putyou out of business.The members of the Saw Manufacturer's Institute havebeen a significant contributor to the state of thediamond blade art. We hope that some of theknowledge and experience that we have accumulatedin our many years in the business can, through thisbooklet, assist you in keeping your cost down to anabsolute minimum.Of all the problems that confront diamond blade users,blade wear is the most difficult to accurately evaluate.Reporting life performance of identical diamond bladespecifications operating under seemingly identicalconditions tend to be inconsistent.Masonry blade operators frequently report blade life interms of hours, days or weeks. However, these reportsneglect to mention type of material being cut, the sizeof the cuts, and the number of cuts per day. In addition,the amount and the cleanliness of the water and theamount of pressure the operator applies to the cuthave an effect on blade life.Obviously, trying to compare the life of one diamondblade with another, simply on the basis of hours, isanalogous to trying to compare a set of tires on one carwith an identical set on another car...it is virtuallyimpossible. There are just too many variables...theweight of the car, the types of roads driven on, thecondition of the car...particularly the suspension, themanner in which the operator handles the car, etc. Justas many variables apply to diamond blades.So, the next time you have reason to compare bladelife, keep these variables in mind. Some of theproblems arising from these variables can be quicklyidentified, and possibly corrected"...Excerpt from: Rx for Diamond Blades, Problems,Causes, Effects, Remedies, published by the Masonryand Concrete Manufacturers Institute.IMPROPER USE OF A DIAMOND BLADE WITh ThECRACK SAW CAN RESULT IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 13PROPER OPERATIONAL USE OF A DIAMONDBLADE ThAT DOES NOT MEET INDUSTRySPECIFICATIONS AND/OR SAFETy STANDARDSWITh ThE CRACK SAW CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.General Information1) " Only mature, properly instructed adults should bepermitted to operate machinery and tools.2) Only utilize the blade to cut the material it isdesigned and intended to cut. Blades intended formasonry material (stone, concrete bricks, blocks) orblades for steel or ductile iron must only be used inthose materials. If you need to cut a material other thanthe ones listed above, you must use a blade that hasbeen designed for that specific material. Use of a bladein the wrong material may involve a considerablesafety risk. It may also reduce the life of the blade ordamage the blade.3) Inspect all diamond blades for damage before use.4) Never use a new or used diamond blade that showsdamage such as cracks, missing segments, damage tothe arbor hole or by the flange washers, or otherappearances not consistent with the appearance of anew blade. These are indications of previous improperuse. If you have any doubt about the safety of a blade,contact the Customer Service Department of the blademanufacturer for assistance. If you do not know thename of the blade manufacturer, contact the CustomerService Department of General Equipment Companyfor assistance. There is no charge for this service.5) Always check that the two mounting flanges are ofthe same diameter and that they are clean and flat. Theflanges should not have any cracks or show anyabnormal wear. Make sure that the arbor bolt or nut isthe correct one for the equipment without damage tothe threads. Improper or damaged flange washersand/or damaged fasteners can damage the blade orcause the blade to come loose from its mount. A bladethat comes loose can cause serious bodily injury ordeath to the operator or bystander. If there are anyquestions regarding the suitability of a specificmounting flange, contact the Customer ServiceDepartment for assistance BEFORE utilizing thediamond blade. There is no charge for this service.6) Always make sure that the arbor hole in the bladematches the one on the equipment. Do not force theblade onto the spindle. Do not use an arbor shaft(spindle) and blade combination of different sizes.Proper fit is achieved when the blade slides onto thearbor without having more than 0.1 mm (0.005 inch)radial play.7) Always tighten the bolt or nut for the flange washersin accordance with the equipment manufacturer'sspecifications.8) Always make sure that the equipment used is ingood operating condition in accordance with themanufacturer's specifications. Do not operate theequipment unless the guards are in good condition, inthe proper place and secure. If the equipment appearsto be missing any fasteners or has any parts thatappear loose or worn, do not operate the equipmentuntil the appropriate repairs are performed. Alwaysmake sure the blade you intend to use with theequipment meets all the equipment manufacturer'sspecifications.9) Do not operate the equipment with other than therecommended blade sizes. This can result in severeblade damage. Contact the machine manufacturer foradvice.10) Make sure that the spindle speed on the machinedoes not exceed the maximum RPM indicated on thediamond blade. This can result in blade breakage.Check the blade shaft with a tachometer to verify thatthe equipment's maximum RPM does not exceed themanufacturer's specifications.11) Blades designed for wet cutting must be cooled byan adequate, continuous water flow to each side of theblade. Lack of enough coolant will cause excessiveheat, poor blade performance and possible segmentloss.12) Blades designed for dry cutting may be usedwithout water coolant. However, dry cutting blades canoverheat which will result in loss of blade tension andmay ruin the blade. The risk is greatest during longcontinuous cutting. Most overheating problems can beavoided by lifting the blade out of the cut and letting itCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 14cool by rotating in the air for 15 to 20 seconds afterevery one minute of cutting.13) Do not force the tool into the material to be cut. Aproperly working diamond tool will grind the materialwithout excessive force being applied. If excessiveforce is needed, it indicates there is damage to theblade or the wrong blade is being used.14) Always inspect the diamond blade and theequipment any time you stop during the cut. If younotice any difference in performance as your workprogresses, immediately STOP and inspect theequipment and the diamond tool.15) Do not operate any diamond tool without fullknowledge about appropriate cooling of the tool. If atool is not cooled properly, the blade core can becomedamaged resulting in the segments coming loose orthe blade core (the steel) breaking. This can result inserious bodily injury or death to the operator orbystander.16) Do not allow any bystanders in the work area.Never allow anyone to stand in front of a saw that isabout to be started or is running.StandardsThe manufacturing of machinery and grinding wheelsand the usage of these products are covered in severalOSHA and ANSI standards. The most applicablestandard for these products is ANSI B7.1 and B7.5.Copies of these standards can be obtained from theAmerican National Standards Institute, 1430Broadway, New York, NY 10018.Personal Safety Equipment1) Always wear dust masks (respirators) approved foruse in concrete and stone dust.2) Always wear approved eye protection such asgoggles or face shield.3) Always wear approved hearing protection.4) Always wear approved head protection.5) Always wear approved safety footwear.6) Always wear approved gloves.NoteIn the manufacturing of all diamond blades differentmetals are used such as Boron, Copper, Colbalt,Nickel, Iron, Tungsten, Molybdenum, Tin, etc., asoutlined in the Material Safety Data Sheet (MSDS).This product as sold presents no hazard although,during use, small amounts of these metal substancesmay be released into the dust or slurry generated fromthe material being cut or ground. Prolonged exposureto excessive amounts of dust and slurry may causerespiratory disease, skin irritation or cancer.Common SenseAlmost all accidents are avoidable if you apply cautionand common sense. Follow all safety precautions at alltimes. If you are not sure...simply don't do it. Ask foradvice. Used improperly or carelessly any tool isdangerous and may cause severe bodily injury ordeath. If tools are used with caution, proper techniquesand common sense, they will do an excellent job foryou"...Excerpt from: Instructions for the Safe Use of DiamondTools, published by Dimas Industries.INSTALLING A DIAMOND BLADE ON ThE ARBORShAFT.Application: All ModelsTools required: 1 each, 3/4 inch wrench1 each, PN CS8-0400 1-1/2 inch wrench or equivalentWhEN INSTALLING A DIAMOND BLADE ON ThEARBOR ShAFT ALWAyS WEAR ThEAPPROPRIATE SAFETy EyEWEAR AND APPARELTO MINIMIZE ThE POTENTIAL FROM FLy INGDEBRIS. FLy ING DEBRIS CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy. 1) If the Crack Saw is powered by an engine,disconnect the spark plug wire. If powered by anelectric motor, properly disconnect the extension cordor Crack Saw from the power source.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 152) Rotate the height adjustment lever counterclockwiseto raise the blade to its maximum position above thework surface, FIGURE 1.FIGURE 13) Position the quick change height lever over center toits rear most (up) position, FIGURE 2.FIGURE 2IMPROPER BLADE POSITION DURING ThESTARTING PROCEDURE CAN ALLOW ThE BLADETO CONTACT ThE WORK SURFACE BEFORE ThEOPERATOR CAN ASSUME A PROPER OPERATINGPOSITION. ThIS OCCURRENCE CAN RESULT INPROPERTy DAMAGE AND/OR PERSONALINJURy .4) Remove the blade guard from the main frame withthe 3/4 inch wrench to expose the arbor shaft. Usingthe 1-1/2 inch wrench, remove the hexagon nut andhub flange from the shaft. The arbor shaft incorporatesleft hand threads, FIGURE 3.FIGURE 35) Inspect the hub flange, hub body and arbor shaft forproper structural integrity. Determine that allcomponents are free from surface imperfectionsincluding, but not limited to corrosion, cracks, warpageand material build-ups. Remove any material build-upfrom the mating surfaces of the hub components.Replace any questionable component with a factoryapproved replacement part only. If there are anyquestions regarding the suitability of a specificcomponent, contact the Customer Service Departmentfor assistance BEFORE utilizing the Crack Saw. Thereis no charge for this service, FIGURE 4.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 16FIGURE 46) Inspect the diamond blade for proper structuralintegrity as outlined above. If there are any questionsregarding the suitability of a diamond blade, contactthe specific manufacturer or the Customer ServiceDepartment of General Equipment Company forassistance BEFORE utilizing it with the Crack Saw.There is no charge for contacting the CustomerService Department of General Equipment Company. 7) Proper blade rotation direction is marked on the sideof the blade blank. The Crack Saw is of a down cuttype design as viewed by the operator. The diamondblade is intended to rotate toward the operator toenhance visibility and overall productivity whilefollowing a random crack. Determine the correctrotation orientation for the diamond blade and install iton the arbor shaft, FIGURE 5.8) Reinstall the hub flange on the arbor shaft and alignthe stud directly with the corresponding hole in theblade blank and hub body. The stud is not designed todrive the diamond blade, FIGURE 6.DO NOT UTILIZE A DIAMOND BLADE ThAT DOESNOT INCORPORATE A DRIVE hOLE FOR ThE hUBFLANGE STUD. DO NOT UTILIZE A DIAMONDBLADE ThAT hAS AN ExCESSIVELy WORN DRIVEhOLE. DO NOT OPERATE ThE CRACK SAW WIThThE hUB FLANGE REVERSED FROM ITS NORMALOPERATING CONFIGURATION TO ENABLE ThEUSE OF A DIAMOND BLADE WIThOUT A DRIVEhOLE. ThE RESULT CAN BE PROPERTy DAMAGEAND/OR PERSONAL INJURy.FIGURE 5FIGURE 69) Reinstall the hexagon nut and tighten with thewrench until the hub flange and body componentsexert consistent, firm clamping pressure against theblade blank. The arbor shaft incorporates left handthreads, making the hexagon nut semi self-tighteningagainst the hub and blade.10) Reinstall and tighten the Blade Guard to the mainframe. DO NOT OPERATE ThE CRACK SAW WIThOUTCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 17ThE BLADE GUARD PROPERLy INSTALLED.OPERATION OF ThE CRACK SAW WIThOUT ThEBLADE GUARD PROPERLy INSTALLED CANRESULT IN PROPERTy DAMAGE AND/ORPERSONAL INJURy.11) If the Crack Saw is powered by an engine,reconnect the engine spark plug wire. If powered by anelectric motor and the machine is to be usedimmediately, reconnect the extension cord or CrackSaw to the power source. Determine that the ON/OFFswitch located on the operator handle is in the OFFposition.UNExPECTED MAChINE START UP CAN RESULTIN PROPERTy DAMAGE AND/OR PERSONALINJURy.12) To remove the diamond blade from the arbor shaft,reverse the steps as outlined above.TRANSPORTING ThE CRACK SAW.Application: All ModelsThe Crack Saw has an operational weight thatprohibits one person from loading and/or unloading italone by conventional, physical efforts.DO NOT ATTEMPT TO LIFT ThE CRACK SAW UPINTO A TRANSPORTATION VEhICLE WITh ThEUSE OF ONE PERSON ALONE. DO NOT ATTEMPTTO LOWER ThE CRACK SAW FROM ATRANSPORTATION VEhICLE WITh ThE USE OFONE PERSON ALONE. LIFT AND/OR LOWER ThECRACK SAW ONLy By ThE USE OF A POWERTAILGATE UNIT, A SUITABLE hOIST UNIT OFPROPER CAPACITy AND/OR CONFIGURATION ORBy ThE USE OF A PROPER q UANTITy OFPERSONNEL IN PROPER PhySICAL CONDITION.The integral lifting bail device(s) can be used tofacilitate lifting by a mechanical device incorporating achain and suitable attachment device. The location ofthe lifting bail(s) may not always locate the exactposition of the center of gravity for the Crack Saw. Typical hoisting configuration for a non Propaneconverted Crack Saw.FIGURE 7 depicts a typical hoisting configuration for anon Propane converted Crack Saw with a mechanicaldevice.FIGURE 7Typical hoisting procedure for the CS8/GhPPropane converted Crack Saw.Because of the mounting location of the Propanecylinder, it is not possible to utilize the integral liftingbails provided on the main frame of the Crack Saw. Tofacilitate hoisting a Propane converted Crack Sawutilize the following procedure:1) Position the Crack Saw on a flat and level surface offirm foundation.2) Inspect the Propane cylinder, all hoses, fittings andconversion components for visible damage and thepotential for leaks. Leaks can be detected by applyinga soap and water mixture to connections with a nonmetallic (spark proof) brush. USE OF A METALLIC AND/OR IMPROPER TyPEBRUSh CAN PRODUCE SPARKS. SUChOCCURRENCE CAN BE ThE IGNITION SOURCEOF AN ExPLOSION, RESULTING IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 183) Inspect the cap screws and related hardware thatsecure the Propane cylinder mounting frame to themain frame for proper structural integrity. Replace anyquestionable fasteners with a factory approvedreplacement part only.4) Turn the Propane cylinder valve to the completelyclosed position.FAILURE TO PROPERLy CLOSE ThE PROPANECyLINDER VALVE CAN RESULT IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.5) Uncouple the hose from the Propane cylinder,FIGURE 8.FIGURE 8IF A TOOL IS REq UIRED TO UNCOUPLE ThEhOSE FROM ThE PROPANE CyLINDER, IT MUSTBE OF A SPARKPROOF CONSTRUCTION TOMINIMIZE ThE POTENTIAL FOR A RANDOMSPARK BEING ThE IGNITION SOURCE OF ANExPLOSION. SUCh AN OCCURRENCE CANRESULT IN PROPERTy DAMAGE AND/ORPERSONAL INJURy.6) Release the latch mechanism that secures thePropane cylinder and remove it from the mountingframe, FIGURE 9. Store the Propane cylinder in anupright position in a properly secured area.FIGURE 9DO NOT ALLOW BySTANDERS OR ANy OBJECTTO COME IN DIRECT CONTACT WITh ThESTORED PROPANE CyLINDER. IMPROPERSTORAGE PROCEDURES CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.7) The lifting bail for the Propane converted Crack Sawis located under the Propane cylinder mounting frame.Attach the mechanical device to the lifting bail tofacilitate lifting the Crack Saw, FIGURE 10.FIGURE 10CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 19ExERCISE ExTREME CAUTION WhEN UTILIZINGA MEChANICAL DEVICE FOR LIFTING ThECRACK SAW. UTILIZE ThE MEChANICAL DEVICEIN ACCORDANCE TO BOTh ITS STATED STATICAND DyNAMIC LOADING ENVELOPES. DO NOTUTILIZE ThE MEChANICAL DEVICE UNTIL ThISINFORMATION IS PROPERLy KNOWN ANDUNDERSTOOD By ALL APPLICABLEPERSONNEL. FAILURE TO PROPERLy UTILIZEThE MEChANICAL DEVICE CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.8) Once on the job site, the Crack Saw can be loweredto the work surface by reversing the above steps.ThePropane cylinder can then be properly reinstalled onthe Crack Saw.General Transportation InformationWhen transporting the Crack Saw on a motor vehicle,the fuel tank breather vent (if so equipped) must becompletely closed to eliminate the accidental seepageof fuel and resulting potential fire and environmentalhazards. If the engine is Propane converted, thecylinder should be removed from the Crack Saw and allvalves, hoses, fittings and related hardware beinspected for proper security and leaks. Transport thePropane cylinder in accordance to all local, State andFederal regulations. Properly secure and store thePropane cylinder to minimize the possibility of propertydamage and/or personal injury. To minimize thepossibility of damage to the Crack Saw, alwaystransport in its normal, upright position. All equipmentmust be secured in/on vehicles with suitable strappingor tie-downs. Personnel should not be transported inthe same compartment as equipment and fuelsupplies. Consult applicable OSHA, AGA, CGA, etc.regulations for the proper transportation of Propaneand other, flammable gases. STARTING ThE CS8/E SERIES ELECTRICALLyPOWERED CRACK SAW ON ThE JOB SITE.1) Position the Crack Saw on a flat and level surface offirm foundation.2) Rotate the height adjustment lever counterclockwiseto raise the blade to its maximum position above thework surface, FIGURE 11.3) Position the quick change height lever over center toits rear most (up) position, FIGURE 12.IMPROPER BLADE POSITION DURING ThESTARTING PROCEDURE CAN ALLOW ThE BLADETO CONTACT ThE WORK SURFACE BEFORE ThEOPERATOR CAN ASSUME A PROPER OPERATINGPOSITION. ThIS OCCURRENCE CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.FIGURE 11FIGURE 12CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 204) Determine that the ON/OFF switch located on theoperator handle is in the OFF position.UNExPECTED MAChINE START UP CAN RESULTIN PROPERTy DAMAGE AND/OR PERSONALINJURy.5) The motor is designed to operate from a clean, 20ampere, 230 VAC, 60 Hz nominal power source. Aclean power source refers to the amperage availableon the individual electrical circuit selected. Additionalelectrical products already utilizing the same circuit willreduce the available amperage, resulting in startingand operational difficulties.6) To minimize the voltage drop to the motor, allextension cords should be copper stranded, 7 AWG orlarger. A NEMA 6-20R twist lock type receptacle isprovided with the CS8/E Series Crack Saw as astandard accessory. The twist lock feature allows theextension cord to be pulled by the Crack Saw withoutbecoming detached. Wire the NEMA 6-20R receptacleto the appropriate extension cord that will be coupledto the NEMA 6-20P plug provided on the Crack Saw,FIGURE 13.FIGURE 137) Properly connect the extension cord to a 230 VAC,60 Hz power source of proper size and capacity.Operating the Crack Saw from a power source ofimproper voltage and amperage will result inunrepairable damage to the electric motor andrelated controls. PROPERLy INSPECT ALL ExTENSION CORDSAND WIRING DEVICES FOR STRUCTURALINTEGRITy. DO NOT UTILIZE A CORD WITh AWORN OR CUT OUTER JACKET MATERIAL. DONOT UTILIZE A CORD WITh ExPOSED INNERWIRES OR INSULATION MATERIAL. DO NOTUTILIZE A CORD ThAT hAS BEEN REPAIREDWITh ELECTRICAL TAPE. USE OF A ANExTENSION CORD OF IMPROPER STRUCTURALINTEGRITy CAN RESULT IN PROPERTy DAMAGEAND/OR PERSONAL INJURy.ALL ELECTRICAL WIRING MUST BE INSTALLEDAND/OR APPROVED IN ACCORDANCE TO LOCALELECTRICAL CODES AND PRACTICES. ANIMPROPER WIRING INSTALLATION CAN RESULTIN PROPERTy DAMAGE AND/OR PERSONALINJURy. 8) Providing proper voltage and amperage levels to theelectric motor is essential to obtain maximumproductivity and service life. Low voltage andamperage levels will cause the motor to overheat. Themotor is equipped with automatic thermal protectiondevice that will stop it before major internal damagecan result. After the motor has cooled to an acceptabletemperature level, the switch must be manuallyactivated to restart, FIGURE 14.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 21FIGURE 149) Couple the NEMA 6-20R receptacle and the NEMA6-20P plug together.10) Grasp the operator handle with firm gripping. Turnthe ON/OFF switch to the ON position. 11) The CS8/E Series electrically powered Crack Sawis not equipped with a centrifugal clutch assembly. Theelectric motor is directly coupled to the arbor shaft by aV-belt reduction.AS SOON AS ThE ELECTRIC MOTOR hASSTARTED, ThE OPERATOR MUST BE IN APOSITION TO ASSUME DIRECT AND FULLCONTROL OF ThE CRACK SAW. FAILURE TOASSUME DIRECT AND FULL CONTROL CANRESULT IN PROPERTy DAMAGE AND/ORPERSONAL INJURy.12) The CS8/E Series electrically powered Crack Sawis stopped by moving the ON/OFF switch located onthe operator handle to the OFF position. For safetyconsiderations, it is also recommended that theextension cord be disconnected from both the CrackSaw and electric power source whenever the CrackSaw is not in use on the job site.If the Crack Saw and/or an individualcomponent/accessory does not appear to befunctioning properly, STOP and do not furtheroperate the Crack Saw until the proper correctiveaction has been completed. If there are anyquestions regarding the proper operation of theCrack Saw, contact the Customer servicedepartment BEFORE further utilization. There is nocharge for this service.STARTING ThE CS8/G SERIES GASOLINEPOWERED CRACK SAW ON ThE JOB SITE.1) Position the Crack Saw on a flat and level surface offirm foundation.2) Rotate the height adjustment lever counterclockwiseto raise the blade to its maximum position above thework surface, FIGURE 15.FIGURE 153) Position the quick change height lever over center toits rear most (up) position, FIGURE 16.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 22FIGURE 16IMPROPER BLADE POSITION DURING ThESTARTING PROCEDURE CAN ALLOW ThE BLADETO CONTACT ThE WORK SURFACE BEFORE ThEOPERATOR CAN ASSUME A PROPER OPERATINGPOSITION. ThIS OCCURRENCE CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.4) Refer to the material supplied by the enginemanufacturer for the correct starting, operation andstopping procedures.5) The CS8/G Series Crack Saw is equipped with anon slip type foot pad to provide additional stabilityduring the engine starting process. FIGURE 17 depictsa proper operator position for starting the Crack Saw.FIGURE 176) The CS8/G Series gasoline powered Crack Saw isnot equipped with a centrifugal clutch assembly. Thegasoline engine is directly coupled to the arbor shaft bya V-belt reduction.AS SOON AS ThE ENGINE STARTS, ThEOPERATOR MUST BE IN A POSITION TO ASSUMEDIRECT AND FULL CONTROL OF ThE CRACKSAW. FAILURE TO ASSUME DIRECT AND FULLCONTROL CAN RESULT IN PROPERTy DAMAGEAND/OR PERSONAL INJURy.7) Allow the engine to properly "warm up" and operatewithout the requirement for choking. Check forexcessive machine noise and/or vibration.DO NOT OPERATE A GASOLINE ENGINE INCLOSED SPACES WIThOUT PROPERVENTILATION. GASOLINE ENGINES PRODUCECARBON MONOxIDE FUMES. BREAThINGCARBON MONOxIDE FUMES CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.ExCESSIVE LEVELS OF CARBON MONOxIDE CANCAUSE DEATh.8) Stop the engine in accordance with the instructionsas described in the material supplied by the engineCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 23manufacturer.If the Crack Saw and/or an individualcomponent/accessory does not appear to befunctioning properly, STOP and do not furtheroperate the Crack Saw until the proper correctiveaction has been completed. If there are anyquestions regarding the proper operation of theCrack Saw, contact the Customer ServiceDepartment BEFORE further utilization. There is nocharge for this service.PROCEDURES FOR ThE SAFE hANDLING OFPROPANE.PROPANE IS AN ExPLOSIVE GAS ThAT CANRESULT IN PROPERTy DAMAGE AND/ORPERSONAL INJURy IF IMPROPERLyTRANSPORTED, hANDLED AND UTILIZED. DONOT SMOKE OR INTRODUCE AN OPEN FLAME INThE VICINITy OF A PROPANE CyLINDER OR ThECRACK SAW AT ANy TIME. CONSULTAPPLICABLE DEPARTMENT OFTRANSPORTATION AND OShA REGULATIONSPERTAINING TO ThE USE OF PROPANE ANDPROPANE CONVERTED Eq UIPMENT.1) PERFORM ALL SERVICE WORK ON ThESURFACE GRINDER IN AN OPEN OR WELLVENTILATED AREA. NEVER ALLOW PROPANEGAS TO ESCAPE IN A CLOSED AREA. PROPANEIS hEAVIER ThAN STANDARD AIR AND MAySETTLE IN LOW AREAS.2) NEVER PERFORM ANy CUTTING, WELDING ORREPAIR PROCESS ThAT INTRODUCES AN OPENFLAME AND/OR SPARKS IN ThE VICINITy OF ThEPROPANE CONVERSION SySTEM.3) hANDLE ThE PROPANE CyLINDERCAREFULLy. DO NOT DRAG OR DROP ThECyLINDER. SUCh ACTION CAN RESULT INPROPERTy DAMAGE AND/OR PERSONALINJURy.4) INSTALLATION, MAINTENANCE AND REPAIRWORK ShOULD BE ACCOMPLIShED Byq UALIFIED SERVICE PERSONNEL.5) NEVER TEST FOR SySTEM LEAKS WITh ANOPEN FLAME. ALWAyS USE SOAP SUDS OR ANAPPROVED LEAK DETECTOR.6) DO NOT FILL A CyLINDER ThAT IS NOTPROPERLy LABELED FOR USE WITh PROPANE.7) DO NOT FILL A CyLINDER ThAT DOES NOThAVE A CURRENT AND/OR VALID hyDROTESTDATE PROPERLy STAMPED ON ITS SURFACE.ExAMPLE OF A PROPANE EMERGENCy PLAN.Operators of the CS8/GHP Crack Saw are advised todesign and implement a Propane emergency plan inthe event that the Propane cylinder, hoses,connections or engine conversion componentsdevelop leaks which allow the Propane to escape intothe atmosphere. Propane is an extremely flammablegas that can cause property damage and/or personalinjury. ThE FOLLOWING INFORMATION IS INTENDED TOPROVIDE A BASIS FOR A PROPANE EMERGENCyPLAN AND IS NOT INTENDED TO BE ALLINCLUSIVE. ThE KEy WORDS WILL BEARRANGED TO SPELL OUT ThE WORDPROPANE.1) PROPANE EMERGENCY. Instruct all personnel toshout out the warning PROPANE EMERGENCY,followed by the location. Example: Propaneemergency, warehouse 2.2) REPEAT THE CALL. Upon hearing the warning,each personnel should repeat the warning.3) OFF WITH ALL UTILITIES. Personnel nearest theutilities should pull all main switches and close allrelated valves.4) PHONE THE FIRE DEPARTMENT. Give thelocation, specific details of the emergency anddirections to the location site. Do not hang up until theCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 24fire department has the complete information itrequires. Carbon dioxide and dry chemical fireextinguishers may be used. NEVER UTILIZECARBON TETRACHLORIDE FIREEXTINGUISHERS.5) ALL TOOLS OFF. Immediately turn off all air,hydraulic and electrically powered tools and machines.6) NO VEHICLES MOVE. No vehicles, even ifelectrically powered are allowed to operate. Shut downall vehicle accessories, including two-way radios.7) EVACUATE NOW. Have all personnel walk to thenearest exit away from the direction of the emergencyarea.STARTING ThE CS8/GhP PROPANE CONVERTEDCRACK SAW ON ThE JOB SITE.1) Position the Crack Saw on a flat and level surface offirm foundation.2) Rotate the height adjustment lever counterclockwiseto raise the blade to its maximum position above thework surface, FIGURE 18.FIGURE 183) Position the quick change height lever over center toits rear most (up) position, FIGURE 19.FIGURE 194) Inspect the Propane cylinder, all hoses, fittings andconversion components for visible damage and thepotential for leaks. Leaks can be detected by applyinga soap and water mixture to connections with a nonmetallic (spark proof) brush.USE OF A METALLIC AND/OR IMPROPER TyPEBRUSh CAN PRODUCE SPARKS. SUChOCCURRENCE CAN BE ThE IGNITION SOURCEOF AN ExPLOSION, RESULTING IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.5) Determine that the Propane cylinder is properlyfastened and secured in the mounting cradle. AN IMPROPERLy SECURED PROPANE CyLINDERCAN BE ThE CAUSE OF DAMAGED/LEAKINGFITTINGS, hOSE AND OThER COMPONENTS,RESULTING IN PROPERTy DAMAGE AND/ORPERSONAL INJURy.6) Open the Propane cylinder valve.7) Move the engine throttle control lever to the 1/4open position.8) Turn the auxiliary engine ignition switch located onCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 25the operator handle to the ON position. Refer to thematerial supplied by the engine and/or Propaneconversion components manufacturers for the correctstarting, operation and stopping procedures, FIGURE 20.FIGURE 209) Propane converted, gasoline engines do not requirethe addition of choke for the starting procedure. Aengine choke control mechanism is not provided on theconverted engine.10) Depress both the regulator and filter buttons forone second, FIGURE 21.11) The CS8/GHP Crack Saw is equipped with a nonslip foot pad to provide additional stability during theengine starting process. FIGURE 22 depicts a properoperator position for starting the Crack Saw.FIGURE 21FIGURE 2212) Start the engine by pulling on the recoil starterhandle. The engine will normally start within 1 or 2pulls. If the engine fails to start, repeat Steps 7 and 8until starting is accomplished.13) The CS8/GHP Propane converted Crack Saw isnot equipped with a centrifugal clutch assembly. Thegasoline engine is directly coupled to the arbor shaft bya V-belt reduction.AS SOON AS ThE CENTRIFUGAL CLUTChASSEMBLy BECOMES ENGAGED, ThEOPERATOR MUST BE IN A POSITION TO ASSUMEDIRECT AND FULL CONTROL OF ThE CRACKSAW. FAILURE TO PROPERLy ASSUME DIRECTAND FULL CONTROL CAN RESULT IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.DO NOT OPERATE A GASOLINE ENGINE INCLOSED SPACES WIThOUT PROPERVENTILATION. GASOLINE ENGINES PRODUCECARBON MONOxIDE FUMES. BREAThINGCARBON MONOxIDE FUMES CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.ExCESSIVE LEVELS OF CARBON MONOxIDE CANCAUSE DEATh.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 2614) Stop the engine in accordance with the instructionsas described in the material supplied by the enginemanufacturer. Turn the auxiliary ON/OFF engineswitch located on the operator handle to the OFFposition.15) Turn the Propane cylinder valve to the completelyclosed position.16) Inspect the Propane cylinder, all hoses, fittings andconversion components for visible damage during useand the potential for leaks. Replace any questionablecomponent with a factory approved replacement only.If the Crack Saw and/or an individualcomponent/accessory does not appear to befunctioning properly, STOP and do not furtheroperate the Crack Saw until the proper correctiveaction has been completed. If there are anyquestions regarding the proper operation of theCrack Saw, contact the Customer ServiceDepartment BEFORE further utilization. There is nocharge for this service.COUNTERACTING ThE PROPANE RE-FRIGERATION EFFECT.The combination of a high Propane flow rate andrelatively small cylinder size (20 lbs.) can produce asudden and drastic reduction in heat output and/orengine stoppage even though a substantial quantity ofPropane remains in the cylinder.Propane in the cylinder is in a liquid state. It must bevaporized before it can be utilized in the internalcombustion process. But vaporization requires theabsorption of heat energy and the source of this energyhas an important bearing upon the operation of theCrack Saw. Since the Propane is enclosed inside the cylinder, thepressure rises. It rises until it reaches a limit for thattemperature. This local pressure, referred to as thevapor pressure, is what delivers the Propane vapor tothe engine. Vapor pressure is a variable entity. Itdecreases as ambient temperature decreases andincreases as ambient temperature increases. If thetemperature of the Propane becomes too low,insufficient pressure will be available to operate theCrack Saw. This can especially happen if the CrackSaw is operated in very cold climates.The problem is that Propane actually cools itself. Thereare two factors that can affect Propane temperature.The first factor is ambient, or the surrounding airtemperature. The second factor has to do with theabsorption of heat energy when liquid Propanevaporizes. As the Propane inside the cylinder begins tovaporize it actually robs or reduces the temperature ofthe Propane that remains. Each pound of Propanerequires 185 BTU just to change states from a liquid toa vapor. The effect is to cool the remaining Propane.The cooling process is known as the refrigerationeffect. If it continues long enough and proceeds fastenough, the Propane temperature and pressure will fallso low that continued operation of the Crack Saw canbe impossible. Even with a full cylinder. Frost oftenforms on the outside of the cylinder as a warning thatexcessive refrigeration is occurring. Fortunately, the refrigeration effect can becounterbalanced by a flow of heat energy into thecylinder from warmer, ambient air. This occurrence isreferred to as convection heating. It can replace muchof the heat energy lost in the course of vaporizingPropane, thus effectively slowing the cooling process.In many cases, convection heating works well enoughto effectively counterbalance the refrigeration effect,but there are still a number of external factors that canreduce efficient convection.The first factor is that the surface area of liquidPropane inside the cylinder decreases with usage. Adecreasing amount of liquid surface area available forconvection heating produces an increase in therefrigeration effect and increased Propane cooling.Let's take the example of a filled cylinder. At first, thePropane temperature drops rapidly as the vaporizingPropane robs the heat energy of the remaining liquidsupply. However, the colder Propane causes heat toflow into the cylinder from the warmer, ambient air. Theprocess remains almost steady state until the heattransfer area (dictated by the amount of liquid Propaneinside the cylinder) is substantially reduced. At thattime, the heat inflow is reduced and accelerates thecooling process of the Propane until the vaporizationrate can no longer be maintained. CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 27Another factor that aggravates the refrigeration effectis increasing the flow rate. Operating the engine at ahigher speed requires a higher fuel flow rate. Propanecooling is directly proportional to the vaporization rate.Many times this rate can not be counteracted byconvection heating. The process drastically reducesthe amount of fuel made available to the engine. Frost accumulation on the cylinder can also impede theefficiency of heating convection. Use of the Crack Sawin high humidity areas can also create the formation offrost on the cylinder. The high water vapor content ofhumid air comes in direct contact with the colderexterior surface of the cylinder and locally freezes.Frost creates an insulation blanket surrounding thecylinder that effectively prevents heat energy transferor convection heating necessary to counterbalance therefrigeration effect.While frost is an enemy, wind actually is an ally. Directexposure to forced convection in the form of windflowing over the cylinder creates a boundary layer. Theboundary layer substantially increases the amount ofconvection heating.There are several other tips that can be demonstratedto reduce refrigeration effect.a) Keep the cylinder filled, especially in cold weather.Never allow the Propane level to fall below 1/3 of itsrated capacity.b) Whenever possible, always store cylinders in awarm storage area.c) The Propane conversion kit includes a vaporizer toassist proper flow rates during operation in coldambient temperatures.d) Watch for and avoid the formation of frost on thecylinder. Keep the cylinder fully exposed to thesurrounding ambient air. Do not cover or protect thecylinder so as to become obstructed.e) Whenever possible, keep the cylinder exposed intothe prevailing wind. This will significantly increase theheat transfer rate and overall utilization time from thecylinder.OPERATING ThE CRACK SAW ON ThE JOB SITE.Application: All ModelsThE SAWING PROCESS PRODUCES ExCESSIVENOISE, VIBRATION AND FLyING DEBRIS. ALLOPERATORS AND WORK PERSONNEL IN ThEVICINITy OF ThE CRACK SAW MUST WEARAPPROPRIATE SAFETy EyE WEAR AND hEARINGPROTECTION DEVICES. OThER SAFETyAPPAREL AND/OR PROCEDURES, DEEMEDNECESSARy By SUPERVISORy PERSONNELMUST ALSO BE WORN AND/OR PRACTICED ByALL APPROPRIATE PERSONNEL.ExERCISE ExTREME CAUTION WhENOPERATING ThE CRACK SAW IN ThE VICINITy OFDECK INSERTS, PIPES, COLUMNS, OPENINGS,LARGE CRACKS, UTILITy OUTLETS OR ANyOBJECT PROTRUDING FROM ThE SURFACE.CONTACT WITh SUCh OBJECTS CAN LEAD TOLOSS OF MAChINE CONTROL, RESULTING INPROPERTy DAMAGE AND/OR PERSONAL INJURy.DO NOT OPERATE A GASOLINE ENGINE INCLOSED SPACES WIThOUT PROPERVENTILATION. GASOLINE ENGINES PRODUCECARBON MONOxIDE FUMES. BREAThINGCARBON MONOxIDE FUMES CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.ExCESSIVE LEVELS OF CARBON MONOxIDE CANCAUSE DEATh.1) The Crack Saw is of a downcut type design asviewed by the operator. The diamond blade is intendedto rotate toward the operator to enhance visibility andoverall productivity while following a random crack.The down cut action results in a "self propelled" effecttoward the operator that substantially enhancesmachine control and reduces fatigue as long as thediamond blade does not come in direct contact with aprotruding obstruction from the floor. Direct contactwith such an obstruction can result in rapid and jerkydirectional movement of the machine. In mostCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 28operating situations, direct contact with a protrudingobstruction from the floor will result in serious damageto the diamond blade. This occurrence may not allowthe operator to remain in proper control of the machine.ALWAyS MAINTAIN PROPER CONTROL OF ThECRACK SAW. IF AN OPERATOR LOOSESCONTROL OF ThE MAChINE, A "RUNAWAy"CRACK SAW CAN RESULT IN PROPERTyDAMAGE AND/OR PERSONAL INJURy. BECAUSEOF ThE UNIq UE OPERATING ChARACTERISTICSOF ThE CRACK SAW, ThERE IS NO PROVISIONFOR ThE ELECTRIC MOTOR/ENGINE TOAUTOMATICALLy STOP IF ThE OPERATOR FAILSTO MAINTAIN PROPER CONTROL.WhEN OPERATING ThE CRACK SAW ON ABOVEGROUND FLOOR LEVELS, ExERCISE ExTREMECAUTION TO PREVENT LOSS OF CONTROL ThATCOULD ALLOW ThE MAChINE AND/OROPERATOR TO FALL DOWN TO LOWER LEVELS.SUCh AN OCCURRENCE CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.2) The crack sawing process is not intended to requireadditional weight to be applied to the machine for thepurpose of increasing productivity and/or stability. Noprovision for attaching weight is made. DO NOT OPERATE ThE CRACK SAW WIThADDITIONAL WEIGhT APPLIED DIRECTLy TO ThEMAChINE TO INCREASE PRODUCTIVITy RATESAND/OR MAChINE STABILITy. PROPERTyDAMAGE AND/OR PERSONAL INJURy CANRESULT. PRODUCTIVITy AND/OR STABILITyRELATED PROBLEMS ShOULD BE DIRECTED TOSPECIFIC MEChANICAL PROBLEMS WITh ThEMAChINE, OPERATIONAL PROCEDURES AND/ORSPECIFIC MEChANICAL PROBLEMS ASSOCIATEDWITh ThE DIAMOND BLADE. CONTACT ThECUSTOMER SERVICE DEPARTMENT FORASSISTANCE. ThERE IS NO ChARGE FOR ThISSERVICE.3) The Crack Saw is designed to be pulled toward theoperator during normal operation to enhance visibilityand overall productivity while the blade follows arandom crack.Operating the Crack Saw by pushing it forward willsubstantially reduce overall productivity andreduce operator control. The diamond blade willdeposit dust and residue materials under the feetof the operator. This configuration will not allowthe machine to be utilized with a vacuum system.This occurrence can also reduce operator stabilityon the work surface and lead to property damageand/or personal injury.4) Position the Crack Saw over the random crack withthe diamond blade directly above and parallel with thecrack direction. Align the front casters of the machineparallel with the crack direction to maximize operatorcontrol at the start of the sawing process, FIGURE 23.FIGURE 235) Turn the height adjustment lever clockwise to lowerthe blade into the crack until the desired sawing depthis achieved. Each full turn of the crank lever willCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 29raise/lower the blade approximately 1/16 inch.6) Following the random crack direction and/or patternwith the blade is accomplished by viewing the bladeand crack in the louvered opening in the blade guard.The louvers are intended to provide protection for theoperator in the event that a diamond segmentbecomes separated from the blade blank. Probablecauses for such occurrences are discussed in detail inthe Trouble shooting section of this manual.a) The geometric design of the louvered blade guard isintended to provide a high mathematical percentage ofprotection for the operator in a normal operatingposition as described in this manual. The mathematicalpercentage will decrease for operating positions notdescribed in this manual. b) In the event of diamond segment separation fromthe blade blank, there is a high mathematicalprobability that the segment will be thrown forwardagainst the dust pan located under the main frame ordirectly against the forward (non louvered) section ofthe blade guard. The manufacturer has conductedextensive testing to substantiate this theory. In actualfield tests, diamond segments were purposelyseparated from the blade blanks through abusiveoperational techniques. In all field tests, no separateddiamond segments made direct contact with the bladeguard louvers.c) In the very low probability that a diamond segmentwould make direct contact with the blade guardlouvers, the geometric design has a high mathematicalprobability to not allow the segment to penetrate thevertical plane as defined by the location of the louvers.The spaces, angle orientation and number of louversminimize the mathematical probability that a segmentcan penetrate the vertical plane, exit the louvers andeventually strike the operator.d) The geometric configuration of the louvers aredesigned to allow for adequate and/or proper visibilityfor the operator during the sawing process. With use,concrete and/or asphalt dust will accumulate at thebottom of the blade guard opening. At regular intervals,this material should be removed to enhance operatorvisibility during the sawing process.DO NOT MODIFy ThE ORIGINAL OPERATINGCONFIGURATION FOR ThE LOUVERS FOR ANyREASON. MODIFICATIONS TO ThE LOUVERS CANRESULT IN PROPERTy DAMAGE AND/ORPERSONAL INJURy.7) Proper operator posture and stance will enhanceoperational safety and overall productivity. FIGURE 24depicts a proper operator's position. FIGURE 25depicts an improper operator's position that canaccelerate fatigue, decrease productivity and reducesafety. The downcut orientation of the diamond bladewill normally produce a "self-propelled" effect againstthe operator. This effect is intended to reduce theoperator fatigue associated with the operation of themachine and to increase overall productivity.8) In some operating conditions, it may be necessaryfor the operator to apply a resisting force (push)against the operator handle to counteract the "self-propelled” effect. In some other operating conditions, itmay be necessary for the operator to apply a force tothe operator handle in order to assist the sawing actionof the Crack Saw.FIGURE 24CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 30FIGURE 25The amount and direction of forces to apply to theoperator handle are governed by but not necessarilylimited to the following factors: a) Average random crack width.b) Diamond blade saw width.c) Sawing depth.d) Tensile strength of the material being sawed.e) Matrix material of the diamond blade segments inconsideration of the aggregate type, amount and/orhardness contained in the material being sawed.f) Service condition of the diamond blade segments.g) Operating RPM speed range for the diamond blade. 9) For normal job applications, operate the engine at amaximum, governed speed of 3450 RPM. Consult thematerial supplied by the engine manufacturer and theSpecifications section for specific information. If youhave any questions regarding specific job applications,contact the Customer Service Department forinformation. There is no charge for this service.Additional information can be obtained from theMasonry and Concrete Saw Manufacturers Institute,30200 Detroit Road, Cleveland, OH 44145-1967.ThE CRACK SAW IS DESIGNED FOR ThE ENGINETO OPERATE AT A MAxIMUM, GOVERNED SPEEDOF 3450 RPM. ThIS ENGINE SPEED AND ThE V-BELT REDUCTION SySTEM ALLOWS ThEDIAMOND BLADE TO OPERATE WITh IN ThEINDUSTRy ACCEPTED RPM SPEED RANGE. FIELDChANGES AND/OR ALTERATIONS MADE TO ThEFACTORy SET ENGINE SPEED RANGE AND/OR V-BELT PULLEy(S) CAN ALLOW ThE DIAMONDBLADE TO OPERATE OUTSIDE ThE INDUSTRyACCEPTED RPM SPEED RANGE. Th ISOCCURRENCE CAN RESULT IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.10) The wide variety of potential work surface materialsalong with the corresponding variety of job siteenvironments, make it impossible to develop astandardized operating procedure for the Crack Saw.Use of the Crack Saw will require constant trial anderror testing until satisfactory results are achieved.Experience gained over time and common sense willhelp minimize the amount of necessary testing. Manyfactors will directly affect the operating parametersand/or techniques utilized for a specialized jobapplication. Some of these factors include:a) Work surface material yield and tensile values. As ageneral rule, these values will determine materialremoval rate per unit of time. Materials with high yieldand tensile values will characteristically resist/limitmaterial penetration. For such materials, the acceptedprocedure is to make a number of multiple passes overthe work surface rather than attempt to make a single,deep pass. The net effect is to actually increaseproductivity: more material removed in less time. Otheradded benefits to this technique are decreasedvibration, less operator fatigue and increasedcomponent service life.b) The width of the random crack in comparison to therequired cutting width and depth. For example, if therandom crack has an average width of 1/8 inch,productivity rates will be greater with the use of a 1/4inch wide blade over that delivered by a 1/2 inch wideblade. The same analogy can also be used for thecutting depth. Productivity rates will be greater for a 1/2inch deep cut than a 1 inch deep cut. Deeper cuts alsorequire additional time for the blade to "clear itself"when following a random crack pattern.11) The sawing process on many work surfacematerials can produce sparks, dust and other foreignCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 31particle contamination.SPARKS PRODUCED By ThE ACTION OF ThEDIAMOND BLADE AGAINST ThE WORK SURFACE(FOR ExAMPLE: STRIKING ANChOR BOLTS) MAyCOME IN CONTACT WITh MATERIALS ThAT CANRESULT IN A FIRE AND/OR ExPLOSION. ThISOCCURRENCE CAN RESULT IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.ThE CREATION OF DUST AND OThER FOREIGNPARTICLE CONTAMINATION FROM ThEOPERATIONAL PROCESS CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.FOR SUCh OPERATING CONDITIONS, ALWAySWEAR A NIOSh/MShA APPROVED DUST/MISTRESPIRATOR. CONSULT APPLICABLE OShAREGULATIONS FOR SPECIFIC INFORMATION.12) Dust and other particle contamination can becontrolled by the following methods:a) The Crack Saw is equipped with a 3 inch outsidediameter vacuum tube adaptor located at the front ofthe machine. An industrial type vacuum system can beattached to the Crack Saw to remove/control dust andother particle contamination from the work surface. Ahose clamp is sometimes required to properly securethe vacuum hose to the vacuum tube, FIGURE 26.Use of a vacuum system with the Crack Saw willnot totally eliminate or provide 100 per cent dustand other particle contamination removal from theatmosphere and work surface. Secondary dust andother particle contamination removal proceduresfrom the atmosphere and work surface willnormally be required.FIGURE 26ALWAyS UTILIZE A VACUUM SySTEM TOOPERATE WITh IN ThE SPECIFIC JOB SITEREq UIREMENT. DUST MATERIAL CAN MEETCLASS II OR CLASS III SPECIFICATIONS OF ThENATIONAL ELECTRIC CODE® FOR hAZARDOUSLOCATION CLASSIFICATIONS. CONSIDERATIONMUST ALSO BE GIVEN TO ThE CREATION OFhAZARDOUS TyPE MATERIALS REq UIRINGSPECIFIC DISPOSAL PROCEDURES. DETERMINEThAT ThE VACUUM SySTEM IS PROPERLyDESIGNED TO OPERATE WITh IN ThESEATMOSPhERES. CONSULT CURRENT NATIONALELECTRIC CODE®, OShA AND ENVIRONMENTALPROTECTION AGENCy REGULATIONS FORSPECIFIC INFORMATION.b) A water stream directed to the blade can be aneffective method of reducing dust effects andincreasing service life at the same time. The optionalCS8-1000 Water Feed System Kit can be installed todirect a continuous stream of water to both sides of thediamond blade, FIGURE 27. The kit includes astandard globe type valve to control water feed ratesand is directly coupled to a water hose. Potentialnegative effects of this procedure is that the water andslurry mixture will require additional time for disposaland proper drying before crack filling work can beinitiated. Under specific circumstances, the resultingslurry mixture can also be classified as a hazardousmaterial, requiring proper disposal procedures.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 3213) The Crack Saw is equipped with a quick changeheight lever designed to raise the diamond blade clear of the work surface when deployed to its maximum upposition, FIGURE 28. FIGURE 27FIGURE 28The quick change height lever is intended to provide afast method to raise the blade for the followingreasons:a) When the sawing process is completed for a randomcrack, the blade can be quickly raised from the worksurface and the machine moved by the operator toanother random crack on the job site. Lowering thequick change lever to the full down position will returnthe diamond blade to the specific depth as originallydetermined by the height adjustment lever, FIGURE29. The quick change height lever is intended toproduce uniform sawing depths for any specific jobapplication.FIGURE 29ExERCISE ExTREME CAUTION WhEN MOVINGThE CRACK SAW ON ThE JOB SITE WITh ThEPOWER SOURCE RUNNING AND ThE q UICKChANGE hEIGhT LEVER OVER CENTER TO ITSREAR MOST (UP) POSITION. IN ThIS OPERATINGCONFIGURATION, ThE DIAMOND BLADE CANCOME IN DIRECT CONTACT WITh FOREIGNOBJECTS AND ThE WORK SURFACE ITSELF. ThISOCCURRENCE CAN SUBSTANTIALLy REDUCEMAChINE CONTROL AND PRODUCE FLy INGOBJECTS, RESULTING IN PROPERTy DAMAGEAND/OR PERSONAL INJURy. CAUTION ALLONLOOKERS REGARDING ThE POSSIBILITy OFFLyING OBJECTS.b) If the sawing process overloads the power source tocause complete stoppage, the diamond blade can bereadily raised by the operator to clear the work surfacebefore the power source is restarted.DO NOT START AND/OR RESTART ThE POWERSOURCE WITh ThE DIAMOND BLADE IN DIRECTCONTACT WITh ThE WORK SURFACE. BEFORESTARTING AND/OR RESTARTING ThE POWERSOURCE, RAISE ThE q UICK ChANGE hEIGhTLEVER OVER CENTER TO ITS REAR MOST (UP)CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 33POSITION TO ALLOW ThE DIAMOND BLADE TOCOMPLETELy CLEAR ThE WORK SURFACE. IFThIS ACTION DOES NOT COMPLETELy RAISEThE DIAMOND BLADE FROM ThE WORKSURFACE, DETERMINE ThAT A BLADE OFPROPER DIMENSIONS IS BEING UTILIZED. IFThERE ARE ANy q UESTIONS REGARDINGPROPER BLADE DIMENSIONS FOR USE WIThThE CRACK SAW, CONTACT ThE CUSTOMERSERVICE DEPARTMENT FOR SPECIFICINFORMATION. ThERE IS NO ChARGE FOR ThISSERVICE.STARTING AND/OR RESTARTING ThE CRACKSAW WITh ThE DIAMOND BLADE IN DIRECTCONTACT WITh ThE WORK SURFACE CANSUBSTANTIALLy REDUCE MAChINE CONTROL,RESULTING IN PROPERTy DAMAGE AND/ORPERSONAL INJURy.14) Generally speaking, the majority of random crackpatterns follow a predominantly straight line with nomore than 20° variance from an imaginary center line,FIGURE 30. These random crack patterns are easilysawed to the required widths and depths by theproperly described diamond blades. FIGURE 30However, there are many instances where the randomcrack pattern follows perpendicular (90°) to moreobtuse (91° to 179°) angles, FIGURE 31. Theseangles will generally not allow the Crack Saw toproperly follow the resulting patterns withoutsignificantly reducing operator control, overallproductivity and causing severe damage to thediamond blade.FIGURE 31These types of patterns can be properly sawed by amultiple step process. A segment of the crack is firstsawed by the described process (FIGURE 32) and themachine repositioned by the described procedure tosaw the intersecting segment, FIGURE 33. Thisprocedure can be repeated as necessary by thegeometry of the specific random crack pattern.Following this procedure is especially important whendeep (greater than 1/2 inch) saw cuts are required forproper crack filling methods. By utilizing this operatingprocedure, intricate random crack patterns can beproperly sawed while maximizing operator control,overall productivity and extending blade service life.FIGURE 32CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 34FIGURE 33IMPROPER SAWING PROCEDURES FOR ANySPECIFIC RANDOM CRACK CAN SUBSTANTIALLyREDUCE OPERATOR CONTROL, OVERALLPRODUCTIVITy AND CAUSE SEVERE DIAMONDBLADE DAMAGE, RESULTING IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.15) Increased productivity rates can usually beachieved in intricate random crack patterns with theuse of a wider diamond blade, FIGURE 34.FIGURE 3416) Normal usage of the Crack Saw will allow the build-up and accumulation of work surface materials oninterior surfaces. It is highly recommended that boththe interior and exterior surfaces be properly cleanedafter the completion of each usage.Failure to properly clean the interior surfaces ofthe Crack Saw can result in dried material build-upand accumulation directly affecting bearing and V-Belt service life.ExERCISE ExTREME CAUTION WhEN UTILIZINGANy SOLVENT TO REMOVE ACCUMULATEDMATERIALS FROM ThE SURFACES OF ThEMAChINE AND RELATED COMPONENTS. MANySOLVENTS ARE FLAMMABLE. DO NOT SMOKEOR INTRODUCE FLAME IN ThE WORK AREA.PROVIDE ADEq UATE VENTILATION AND WEARPROPER SAFETy APPAREL.PROPERLy DISPOSE OF ALL ACCUMULATEDMATERIALS PER OShA AND ENVIRONMENTALPROTECTION AGENCy CODES ANDREGULATIONS. MANy ACCUMULATEDMATERIALS CAN BE CLASSIFIED AShAZARDOUS AND REq UIRE PROPER DISPOSALPROCEDURES. CONTACT ThE APPLICABLEGOVERNMENT AND/OR PRIVATE AGENCIES FORSPECIFIC INFORMATION.17) On job applications where the work processcreates a considerable amount of loose material, it canbecome almost impossible to determine proper cuttingdirection for the blade and the extent of work alreadyaccomplished. The problem can be compounded if avacuum system is not utilized. Loose material shouldbe removed by sweeping or other, appropriateprocesses. The Crack Saw can then be utilized untilconditions again warrant removing the accumulatedmaterial.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 35STOPPING ThE CS8/E SERIES ELECTRICALLyPOWERED CRACK SAW.1) Position the quick change height lever over center toits rears most (up) location.2) Stop the Crack Saw by moving the ON/OFF switchlocated on the operator handle to the OFF position. Forsafety considerations, it is also recommended that theextension cord be disconnected from both the CrackSaw and electric power source whenever the CrackSaw is not in use on the job site.STOPPING ThE CS8/G SERIES GASOLINEPOWERED CRACK SAWS.1) Position the quick change height lever over center toits rear most (up) position.2) Stop the Crack Saw by moving the engine throttlecontrol lever to the idle speed position. Turn the ignitionswitch located on the engine to the OFF position.Consult the material supplied by the enginemanufacturer for specific information.STOPPING ThE CS8/GhP PROPANE CONVERTEDCRACK SAW.1) Position the quick change height lever over center toits rears most (up) position.2) Stop the Crack Saw by moving the engine throttlecontrol lever to the idle speed position. Turn theauxiliary ignition switch located on the operator handleor the ignition switch located on the engine to the OFFposition. Consult the material supplied by the enginemanufacturer for specific information.3) Turn the Propane cylinder valve to the completelyclosed position.4) Inspect the Propane cylinder, all hoses, fittings andconversion components for visible damage during useand the potential for leaks. Replace any questionablecomponent with a factory approved replacement only.OPERATIONAL PARAMETERS AND TEChNIq UESFOR ThE CS8 SERIES CRACK SAW.Application: All ModelsBasic definitionsThere are very few aspects of the pavementmaintenance industry that all members, includingcontractors, engineers, researchers and governmentagencies can agree on except the inevitability of cracksforming in all types of pavements. To properly addressthe crack repair procedures, contractors must have abasic understanding of why crack repair is beneficial,crack types to address and the repair materials andmethods available.A basic understanding of the difference between crackfilling and crack sealing and the working knowledge tounderstand which one is appropriate for a specific jobapplication is essential for any pavement maintenancecontractor.An industry accepted definition of crack filling is theplacement of materials into cracks to reduce waterintrusion and reinforce the adjacent pavement. Cracksealing is the placement of specialized materials eitherabove or into working cracks to prevent the intrusion ofwater and incompressibles such as sand, aggregateand dirt.Why Do It at All?Crack sealing is used as a first line of defense againstthe deterioration of pavement because of its inherentbenefits:a) It protects the base and subbase. A good pavementrequires a base and subbase of high structuralintegrity. Effective crack sealing procedures eliminatewater from entering and weakening these areas. Theresulting weakness can result in the loss of structuralsupport, which can then further result in the formationof additional cracks and settling around the crack area.b) It preserves the pavement adjacent to the cracking.Cracks that are properly cleaned and sealed containfiller materials that firmly adhere to the crack sidesduring times of both expansion and contraction.Without the addition of these filler materials, theadjacent pavement would have increased exposure tothe elements, resulting in increased oxidation of thebinder, hardening and secondary cracking along themain crack.c) It eliminates the damaging effects ofCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 36incompressibles such as sand, aggregate and dirt.When these materials get into a crack they can restrictcrack closure during periods of warm weather. Theresulting compressive stresses at the faces can createspalling and loosening. In some highly oxidizedpavements these stresses can even create pavementlipping, which is the upheaval of pavements at theirtransverse cracks.d) It extends pavement life. Sealing procedures allowthe contractor to effectively exert control over the baseand subbase conditions, pavement interference andcrack growth, thereby extending the pavement'sservice life.Types of Cracks.There are several basic types of cracks:a) Reflective. This type of crack appears primarily inresurfacing projects, although it can also occur in anew pavement surface. Reflective cracks occur whenan existing crack or joint in the underlying pavementstructure reflects upward through the surface.b) Joint. A joint is the edge of the individual paving passmade during construction. Such construction jointsusually have a lower density than the remainingmaterial. When the placed mats do not bond properly(for any number of reasons), joint cracks can appear.c) Slippage. Slippage cracks are usually crescentshaped and are created by heavy traffic that is eitherstopping, turning or climbing a hill. Resultant stressescan cause a bond failure between upper and lowerpavement layers. The open end of the U shaped crackalways points in the direction of the applied force. d) Thermal. All pavements expand and contract due totemperature variations. This movement can createcracks. To better allow for movement, pavements needto be constructed with the correct percentage of airvoids, which provide for internal stress relief. When theair void percentage is not correct, thermal cracksappear.e) Fatigue or alligator. Over time, as a pavementsurface ages, it becomes more rigid and has lessability to tolerate vertical load deflections. Thisoccurrence creates a tension and pulling apart in thepavement and results in alligator type cracking. Suchcracking can also occur from improper structuralcapacity and aging. It is generally recommended thatalligatored areas be removed and replaced rather thanbe filled or sealed.f) Block. This type of crack forms a square pattern, withcracks intersecting at approximate right angles. Acommon cause of block cracks on asphalt pavementsis a lack of traffic, which constantly kneads thepavement and keeps it flexible. Other causes caninclude excessive air voids in the material.g) Edge. Edge cracks appear only parallel to and withinusually 18 inches of the pavement edge. Cause caninclude substandard base, lack of shoulder support,inadequate drainage or damage caused by frost.Equipment and Materials.Pavement contractors can select from a wide variety ofhot or cold applied materials to seal cracks. Unlike coldmaterials, hot applied sealers are first prepared priorto application. The standard method is a double boilerkettle, which consists of an inner chamber thatcontains and agitates the sealant material and an outerchamber serving as the heat source.Heated sealers include rubberized asphalt, lowmodulus rubberized asphalt, fiberized asphalt andasphalt rubber. Cold applied materials are usuallycomprised of a self leveling silicone and modifiedemulsions.When making a material selection, the pavementcontractor must consider many factors. It is critical thatthe material be placed efficiently and deliversatisfactory performance given the relatedenvironmental factors. Other significant factors includepreparation and cure times, adhesiveness to the cracksides, cohesiveness in the crack center, resistance tosoftening and flow, aging and weathering.Preparation and Application.The primary purpose of the Crack Saw is to produce aproper configuration in the crack area for theplacement of the sealing material. The exactconfiguration is dependent upon many factorsincluding crack type, pavement downtime and budgetrestrictions. There are numerous configurations,although all can be grouped into four generalclassifications:CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 37a) Flush fill. The material is simply dispensed into anexisting unsawed crack and the excess struck off.b) Reservoir. Material is placed only within the confinesof a sawed crack, either flush with or slightly below thepavement surface.c) Overband. Material is placed into and over anunsawed crack and shaped into either a band aidconfiguration (3 to 5 inches wide and 1/8 inch thick) orgiven a slight cap. d) Combination. Material is placed into and over asawed crack, then is shaped by squeegee into a bandcentered over the crack reservoir.The configuration of the random crack ultimatelydetermines the specific type and/or quantity of materialutilized in the process.ServicePREVENTATIVE MAINTENANCE ChECK LIST.Application: All ModelsThe normal operation of the Crack Saw producesextreme dirt and dust, along with levels of randomvibration. Before operating the Crack Saw, thefollowing service list should be accomplished. This listis for reference only and is not intended to be allinclusive. Other subject areas can be added at thediscretion of the owner(s) and/or operator(s):1) Check all fasteners for proper torque values. If afastener requires retorquing, consult a torque chart forproper value. Properly discard and replace any wornfastener with a factory approved, replacement part.2) Check the V-belts for wear. Adjust or replace asnecessary. Check pulleys for wear and properalignment. Many loose materials created as a result ofoperating processes can be extremely abrasive.3) Keep the Crack Saw clean. Wash the unit after eachuse. Keep loose materials from accumulating aroundengine cooling fins. Determine that the interior sectionsof the frame are free of material build-up. Such a build-up can restrict the operating process and present apotential safety hazard. Clean and remove anymaterial build-up from the Crack Saw after each use.4) Engine service life can be extended with proper aircleaner maintenance. Consult the material supplied bythe engine manufacturer for specific information.5) Check for proper oil level. Always use clean, highquality engine oil. Change oil as required. Consult thematerial supplied by the engine manufacturer forspecific information.6) Remove material accumulations from the exteriorsurfaces of the electric motor. The electric motor is atotally enclosed, fan cooled (TEFC) design. Keep thefan fins clear of material accumulations to enhance airflow over the motor exterior for cooling purposes.DO NOT PERFORM PREVENTATIVEMAINTENANCE ChECKS WITh ThE ENGINE ORELECTRIC MOTOR RUNNING. STOP ThE POWERSOURCE AND DISCONNECT ThE SPARK PLUGOR ExTENSION CORD BEFORE PERFORMINGANy MAINTENANCE TO ThE CRACK SAW. IFGASOLINE ENGINE POWERED, RECONNECT ThESPARK PLUG BEFORE RESTARTING ThE ENGINE.IF ELECTRIC MOTOR Eq UIPPED, TURN ThEON/OFF SWITCh TO ThE OFF POSITION BEFORERECONNECTING ThE ExTENSION CORD.IMPROPER PROCEDURES CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.ChECKING V-BELT TENSION AND ALIGNMENT.Application: All ModelsProper V-belt tension and alignment is essential forsmooth transmission of horsepower and extendedservice life. Improper tension and alignment willaccelerate V-belt wear and contribute to decreasedproductivity. The V-belt is tensioned at the factory withthe maximum recommended tension force. Check thebelt tension at least two times during the first day ofoperation as there will normally be a rapid decrease inbelt tension until it has been run in. Check the belttension every eight hours of operation thereafter andmaintain tension within the recommended range. Thecorrect operating tension for a V-belt drive is the lowestCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 38tension at which it will not slip under peak loadconditions.Tools Required:1 each, 16 inch minimum length straightedge.1 each, 10 lbs minimum capacity, tension scale or belttension tool.1) Position the Crack Saw on a suitable work benchwith the V-belts approximately at waist level.2) If the Crack Saw is powered by an engine,disconnect the engine spark plug wire. If powered byan electric motor, disconnect the extension cord orCrack Saw from the power source. If the Crack Saw isequipped with a Propane converted engine, thePropane cylinder must be removed from the mainframe to better facilitate the maintenance process.Determine that the Propane cylinder valve is fullyclosed before uncoupling the hose. Secure in a properstorage area. FAILURE TO PROPERLy CLOSE ThE PROPANECyLINDER VALVE CAN RESULT IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.IF A TOOL IS REq UIRED TO UNCOUPLE ThEhOSE FROM ThE PROPANE CyLINDER, IT MUSTBE OF A SPARKPROOF CONSTRUCTION TOMINIMIZE ThE POTENTIAL FOR A RANDOMSPARK BEING ThE IGNITION SOURCE OF ANExPLOSION. SUCh AN OCCURRENCE CANRESULT IN PROPERTy DAMAGE AND/ORPERSONAL INJURy.DO NOT ALLOW BySTANDERS OR ANy OBJECTTO COME IN DIRECT CONTACT WITh ThESTORED PROPANE CyLINDER. IMPROPERSTORAGE PROCEDURES CAN RESULT INPROPERTy DAMAGE AND/OR PERSONAL INJURy.3) Remove the belt guard from the main frame. Cleanthe inside of the belt guard with an appropriate solvent.Check for signs of wear and damage. Secure in aproper storage area. Observe all applicable safety precautions for thesolvent.4) Check the belt tension using the spring scale or belttension tool midway between the engine/motor pulleyand the arbor shaft pulley. Belt tension should measureapproximately 0.22 inch at 3-1/4 to 4-3/8 lbs.measured force range, FIGURE 35. If tension is withinspecifications, proceed to Step 5. If tension is notwithin specifications, refer to INSTALLING AREPLACEMENT V-BELT for specific information.FIGURE 355) Belt alignment is checked with the straightedge.Place the straightedge squarely against the arbor shaftpulley. Properly aligned pulleys should also place thestraightedge squarely against the engine/motor pulley.Remove the straightedge and rotate the engine/motorpulley 120 degrees. Recheck alignment with thestraightedge. Repeat the process until theengine/motor pulley is rotated a full 360 degrees.Maximum allowable misalignment is + - 1/32 inch. Ifpulley alignment is not within specifications, refer toCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 39INSTALLING A REPLACEMENT V-BELT for specificinformation, FIGURE 36.FIGURE 366) Reinstall the belt guard to the main frame.Determine that all safety related decals affixed to thebelt guard are fully readable. If any decal is not fullyreadable, replace with a factory approved,replacement part only. 7) If the Crack Saw is powered by an engine,reconnect the engine spark plug wire. If powered by anelectric motor and the machine is to be usedimmediately, reconnect the extension cord or CrackSaw to the power source. Determine that the ON/OFFswitch located on the operator handle is in the OFFposition. If the Crack Saw is equipped with a Propaneconverted engine, properly install the Propane cylinderand recouple the hose as outlined in this manual.UNExPECTED MAChINE START UP CAN RESULTIN PROPERTy DAMAGE AND/OR PERSONALINJURy.INSTALLING A REPLACEMENT V-BELT ORPULLEy.Application: All ModelsTools Required:2 each, 9/16 wrenches.1 each, 5/32 Allen wrench.1 each, 16 inch minimum length straightedge.1 each, 10 lbs minimum capacity, tension scale or belttension tool.Parts Required:2 each, PN BX34 V-belt (if required).1 each, PN CS8-0260 pulley assembly (if required).1 each, PN CS8-0270 pulley assembly (if required).1) Position the Crack Saw on a suitable work surfacewith the V-belts approximately at waist level.2) If the Crack Saw is powered by an engine,disconnect the spark plug wire. If powered by anelectric motor, disconnect the extension cord or CrackSaw from the power source. If the Crack Saw ispowered with a Propane converted engine, thePropane cylinder must be removed from the mainframe to better facilitate the maintenance process.Determine that the Propane cylinder valve is fullyclosed before uncoupling the hose. Secure in a properstorage area. Using the 9/16 inch wrenches, removethe belt guard from the main frame. Clean the inside ofthe belt guard with an appropriate solvent. Check forsigns of wear and damage. Secure in a proper storagearea.FAILURE TO PROPERLy CLOSE ThE PROPANECyLINDER VALVE CAN RESULT IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.IF A TOOL IS REq UIRED TO UNCOUPLE ThEhOSE FROM ThE PROPANE CyLINDER, IT MUSTBE OF ThE SPARKPROOF CONSTRUCTION T0MINIMIZE ThE POTENTIAL FOR A RANDOMCRACK BEING ThE IGNITION SOURCE OF ANExPLOSION. SUCh AN OCCURRENCE CANRESULT IN PROPERTy DAMAGE AND/ORPERSONAL INJURy.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 40DO NOT ALLOW BySTANDERS OR ANy OBJECTTO COME IN CONTACT WITh ThE STOREDPROPANE CyLINDER. IMPROPER STORAGEPROCEDURES FOR ThE PROPANE CyLINDERCAN RESULT IN PROPERTy DAMAGE AND/ORPERSONAL INJURy.Observe all applicable safety precautions for thesolvent. 3) Remove the belt guard from the main frame. Cleanthe inside of the belt guard with an appropriate solvent.Check for signs of wear and damage. Secure in aproper storage area.4) Using the 9/16 inch wrenches, loosen theengine/motor mounting capscrews.5) With the same wrenches, rotate the engine take-upcapscrews counterclockwise to loosen the V-belts andallow the engine/electric motor to slide toward theoperator handle, FIGURE 37.6) Remove the worn V-belts. Inspect theengine/electric motor and arbor shaft pulleys for wearand damage. Install the replacement belts, PN BX34in pairs. The Crack Saw utilizes two V-belts. Alwaysinstall replacement belts in matched pairs. Neverreplace just one of the V-belts.Do not operate the Crack Saw with only one V-beltinstalled. One V-belt is not capable of transmittingproper horsepower and torque levels to the arbor shaft.a) Do not install replacement belts if the pulleys haveexcessively worn grooves. Such pulleys should bereplaced to insure proper belt fit. Operating the V-beltsin worn pulley grooves will accelerate wear, reducehorsepower and torque levels and significantly reducecomponent service life.b) A V-belt should never be forced over a pulley. Morebelts are broken from this cause than from actualfailure in service.c) Keep the belts as clean and free of foreign materialas possible. Do not use belt dressing.FIGURE 377) Tighten the engine/electric motor attachment capscrews until they just begin to apply tension to theengine/electric motor. DO NOT OVER TIGHTEN.Alternately tighten the take-up cap screws until slighttension is applied to the V-belt.8) Belt alignment is checked with the straightedge.Place the straightedge squarely against the arbor shaftpulley. Properly aligned pulleys should also place thestraightedge squarely against the engine/electric motorpulley. Remove the straightedge and rotate the enginepulley 120 degrees. Recheck the alignment with thestraightedge. Repeat the process until theengine/electric motor pulley has been rotated a full 360degrees. Maximum allowable misalignment is +- 1/32inch, FIGURE 38.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 41FIGURE 389) Apply increased belt tension by progressivelytightening the take-up cap screws against theengine/electric motor.a) Recheck V-belt alignment.b) Check belt tension with the spring scale or belttension tool midway between the engine/electric motorand arbor shaft pulleys. Belt deflection should measureapproximately .20 inch at 4 to 5-1/2 pounds force,FIGURE 39.FIGURE 39c) If the belt tension and alignment are withinspecifications, torque the engine/electric motorattachment cap screws to 35 ft lbs (47 N.m).d) Recheck V-belt tension and alignment.10) Reinstall the belt guard to the main frame. Installthe flat washers and self locking hexagon nuts.Determine that all safety related decals affixed to thebelt guard are fully readable. If any decal is not fullyreadable, replace with a factory approved replacementpart only.11) If the Crack Saw is powered by an engine,reconnect the engine spark plug wire. If powered by anelectric motor and the machine is to be usedimmediately, reconnect the extension cord or CrackSaw to the power source. Determine that the ON/OFFswitch located on the operator handle is in the OFFposition. If the Crack Saw is equipped with a Propaneconverted engine, properly install the Propane cylinderand recouple the hose as outlined in this manual.UNExPECTED MAChINE START UP CAN RESULTIN PROPERTy DAMAGE AND/OR PERSONALINJURy.INSTALLING REPLACEMENT BEARINGS ON ThEARBOR ShAFT.Application: All ModelsTools Required:2 each, 9/16 inch wrenches1 each, 3/4 inch wrench1 each, 5/32 inch Allen wrench1 each, pliers for large, external type snap rings1 each, shop press Parts Required:2 each, PN 5208-2RS sealed bearings1 each, container of bearing and shaft locking grade, anaerobic adhesive/sealant1 each, PN 5160-156 snap ring (if required)1 each, PN CS8-0230 bearing block (if required)1 each, PN CS8-0030 arbor shaft (if required)1) Position the Crack Saw on a suitable work surfacewith the V-belt approximately at waist level.2) If the Crack Saw is powered by an engine,disconnect the engine spark plug wire. If powered byan electric motor, disconnect the extension cord orCrack Saw from the power source. If the Crack Saw isequipped with a Propane converted engine, thePropane cylinder must be removed from the mainframe to better facilitate the maintenance process.Determine that the Propane cylinder is fully closedbefore uncoupling the hose. Secure in a proper storagearea.FAILURE TO PROPERLy CLOSE ThE PROPANECyLINDER VALVE CAN RESULT IN PROPERTyDAMAGE AND/OR PERSONAL INJURy.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 42IF A TOOL IS REq UIRED TO UNCOUPLE ThEhOSE FROM ThE PROPANE CyLINDER, IT MUSTBE OF A SPARKPROOF CONSTRUCTION TOMINIMIZE ThE POTENTIAL FOR A RANDOMSPARK BEING ThE IGNITION SOURCE OF ANExPLOSION. SUCh AN OCCURRENCE CANRESULT IN PROPERTy DAMAGE AND/ORPERSONAL INJURy.DO NOT ALLOW BySTANDERS OR ANy OBJECTTO COME IN DIRECT CONTACT WITh ThESTORED PROPANE CyLINDER. IMPROPERSTORAGE PROCEDURES FOR ThE PROPANECyLINDER CAN RESULT IN PROPERTy DAMAGEAND/OR PERSONAL INJURy.3) Using the 9/16 inch wrenches, remove the beltguard from the main frame. Clean the inside of the beltguard with an appropriate solvent. Check for signs ofwear and damage. Secure in a proper storage area.Observe all applicable safety precautions for thesolvent.4) Remove the V-belt and arbor shaft pulley. Refer toINSTALLING A REPLACEMENT V-BELT OR PULLEYfor specific information. Remove the blade guard fromthe main frame. Clean the interior and exterior surfacesof the blade guard with an appropriate solvent. Checkfor signs of wear and damage.5) Using the 3/4 inch wrench, remove the bearingblock/arbor shaft from the main frame. Clean the arborshaft/bearing block assembly with an appropriatesolvent. Check for signs of wear and damage.6) Position the bearing block/arbor shaft assembly ona suitable work surface. Use the snap ring pliers toremove the snap ring, FIGURE 40.Wear safety glasses and other appropriate safetyapparel when removing the snap ring orperforming any work with an arbor press. Cautionall onlookers about the possibility of flying debrisand personal injury.7) Using the Allen wrench, remove the Allen screwsthat retain the hub body to the arbor shaft. If the hubbody does not freely remove itself from the arbor shaft,position the assembly in a suitable arbor press,FIGURE 41. The hub can be removed by pressing thehub body from the arbor shaft. As the hub bodyseparates from the arbor shaft, the arbor shaft/bearingblock assembly can fall directly to the work surface.FIGURE 40CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 43FIGURE 41Exercise extreme caution when pressing the hubbody from the arbor shaft/bearing block assembly.Improper activities can result in the componentsstriking body parts, resulting in property damageand/or personal injury.8) Position the arbor shaft assembly in a suitable arborpress with the snap ring shoulder facing down.Determine that the bearing block face is properlysupported. The outside diameter of the bearing mustbe clear for axial movement. Press the arbor shaftassembly from the bearing block, FIGURE 42.Reposition the assembly and press the remainingbearing from the bearing block, FIGURE 43.FIGURE 42FIGURE 439) Clean and inspect the arbor shaft and bearing blockfor wear and damage. Replace any questionablecomponent with a factory replacement part only.10) Clean the outside bore diameter of thereplacement bearing with an appropriate solvent. Applya suitable amount of anaerobic adhesive/sealant to theoutside diameter of the bearing. Determine that theoutside diameter of the bearing will absorb the thrustfrom the pressing process. The inside bore of thebearing should not receive any direct thrust force.Press the replacement bearing into the bearing blockuntil it seats itself against the flange, FIGURE 44.FIGURE 4411) Clean the bearing journal areas of the arbor shaftwith an appropriate solvent. Apply a suitable amount ofanaerobic adhesive/sealant to the bearing journal areaCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 44located near the snap ring groove. Press the arborshaft into the replacement bearing until it seats itselfagainst the inner race, FIGURE 45. 12) Clean the inside and outside bore of the secondreplacement bearing with an appropriate solvent.Apply a suitable amount of anaerobic adhesive/sealantto the inside and outside bore. Install the replacementbearing over the arbor shaft. Determine that both theinside and outside bores of the bearing will absorb thethrust from the pressing process. Press thereplacement bearing into the bearing housing until itseats itself against the flange. This procedure willminimize the potential for improper bearing preloading,FIGURE 46.FIGURE 45FIGURE 4613) Reinstall the snap ring into the snap ring groove onthe arbor shaft. Wear safety glasses and other appropriate safetyapparel when removing the snap ring orperforming any work with an arbor press. Cautionall onlookers about the possibility of flying debrisand personal injury.14) Rotate the arbor shaft by hand to determine theamount of bearing preloading created as a result of theinstallation process. Properly installed replacement bearings should rotatewithout excessive friction, drag and/or "rough spots". Ifthese symptoms occur after assembly, the bearingswere improperly supported when pressed into thebearing block. The resulting thrust placed upon thebearing exceeded the static capacity. Bearingoperating with these characteristics will deliver minimalservice life and be prone to premature failure.15) Inspect the hub body drive key and hub body forwear and/or damage. Replace any questionablecomponent with a factory replacement part only.Reinstall the hub body drive key into the arbor shaft.Reinstall the hub body to the arbor shaft until it fullyseats against the inside bore of the bearing. Reinstallthe two Allen screws into the hub body and properlytorque.16) Inspect the arbor shaft drive key and arbor shaftpulley for wear and/or damage. Replace anyquestionable component with a factory replacementpart only. Reinstall the arbor shaft pulley drive key intothe arbor shaft. Reinstall the arbor shaft pulley. Do nottorque the Allen screws at this time. The Allen screwswill be tightened after determining that theengine/electric motor and arbor shaft pulleys are inproper alignment. See Step 19.17) Reassemble the bearing block to the main frame.Determine that the arbor shaft rotates perpendicular toboth the vertical and horizontal planes as defined bythe direction of machine travel.18) Follow the instructions as outlined for INSTALLINGA REPLACEMENT V-BELT OR PULLEY to completeCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 45the assembly of the pulleys, V-belts and belt guard.19) If the Crack Saw is powered by an engine,reconnect the engine spark plug wire. If powered by anelectric motor and the machine is to be usedimmediately, reconnect the extension cord or CrackSaw to the power source. Determine that the ON/OFFswitch located on the operator handle is in the OFFposition. If the Crack Saw is equipped with a Propaneconverted engine, properly install the Propane cylinderas outlined in this manual.UNExPECTED MAChINE START UP CAN RESULTIN PROPERTy DAMAGE AND/OR PERSONALINJURy.LUBRICATION REq UIREMENTS.Application: All ModelsParts Required:1 each, standard grease gun filled with one of the following: ESSO Beacon 325, Shell Alvania #2, Chevron SRI, or equivalent1 each, container of dry film lubricant1) Lubricate the rigid caster wheel bearing with a dryfilm lubricant only. Dry film lubricants dry immediatelyupon contact. Use sparingly. Excess lubricant willattract the fine grained, powdered materials describedin this manual and directly affect bearing service life.Do not lubricate the rigid caster wheels with any type ofgrease material. Grease will attract foreign materialaccumulations that can accelerate bearing wear.2) The arbor shaft is supported by extra capacity, ballbearings. These bearings are lubricated at the time ofmanufacture and do not require additional servicingwhen placing the unit in initial service or during theirnormal service life. During the first few hours ofservice, lubrication material may seep from thebearings. This should not be a cause for immediateconcern.3) The swivel wheel casters are sealed to minimize thepotential for dust contamination. Lubricate the swivelcaster wheels with the grease gun. Use sparingly.Excess lubricant will attract the fine grained, poweredmaterials described in this manual and directly affectbearing service life.4) Do not apply belt dressing materials to the V-beltsfor the purpose of minimizing slippage. These productstypically attract foreign material accumulations that canaccelerate component wear. Excessive V-belt slippagecan be eliminated with proper V-belt tension andalignment.ELECTRIC MOTOR SERVICE.Application: CS8/E Series Crack SawThe electric motor is capable of operating for manyyears with a reasonably small amount of maintenance.Before attempting to service the motor, disconnect theCrack Saw from the power source. Clean the motorsurfaces periodically, preferably with a vacuumcleaner. Heavy accumulations of dirt and lint will resultin overheating and premature failure of the motor.The electric motor is equipped with higher capacity ballbearings and under normal service and ambienttemperatures, should not require relubrication for manyyears. If you feel that the motor requires relubrication,contact the local representative of the motormanufacturer for specific information.The seals utilized with the motor are intended to delivera longer service life in a concrete dust atmosphere.When replacing the seals, utilize only componentsmeeting the original factory specifications.ENGINE SERVICE.CS8/G Series and CS8/GhP Crack SawConsult the material supplied by the enginemanufacturer for specific service and maintenanceinformation regarding:1) muffler2) spark plug3) air filter system 4) carburetor adjustment5) ignition system6) short and long term storage7) maximum governed speedCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 468) emission standardsKeep this information stored with the Operator'sManual for the Crack Saw so it will always be availablefor use when the engine requires service ormaintenance. A properly maintained engine will addconsiderably to the service life and overall productivityof the Crack Saw.TroubleshootingELECTRIC MOTOR.Application: CS8/E Series Crack SawMOTOR FAILS TO START.ON/OFF switch in the OFF position. Turn the switch tothe ON position.Improper voltage selection. Determine the availablevoltage value from the power source.Crack Saw and/or erxtension cord is not plugged intothe power source. Determine that all electricalconnections have been properly made. The NEMA 6-20 Series cap and receptacle set is of a twist lockconfiguration and requires a twist motion to ensure aproper connection.Improper extension cord size and capacity. Operatethe Crack Saw with copper stranded, 7 AWG or largerextension cords. Improper extension cord size andcapacity will result in significant heat rise andcorresponding voltage and amperage drop.Thermal protection device activated. To protect themotor against heat related damage, an automaticthermal proterction switch is provided. High operatingtemperatures will activate the switch and shut themotor off. After the motor has cooled to an acceptablelevel, depress the switch to restart.MOTOR LOSES POWERImproper externsion cord size and capacity. Replacewith cords meeting the required specifications.Excessive extension cord length. Even with properextension cord size and capacity, excessive cordlength can reduce the available voltage and amperageto the motor. Measure the available voltage to themotor where the extension cord connects to the CrackSaw with a voltmeter. Reduce the extension cordlength as required to achieve the minimum voltageoperating specification as required by the motormanufacturer.Insufficient available voltage and amperage at thepower source. Measure the available voltage at thepower source (usually a receptacle) with a voltmeter. Ifthe available voltage is below the minimum operatingspecification as required by the motor manufacturer,utilize an alternative power source.Improper motor cooling. See ELECTRIC MOTORSERVICE.Excessive load to the motor. See OPERATING THECRACK SAW ON THE JOB SITE.ENGINE.Application: CS8/G Series Gasoline Powered andCS8/GhP Propane Converted Crack SawsENGINE FAILS TO START.Ignition switch in OFF or cut off position. Place switchin the ON position or move throttle control lever to theignition operational position.Incorrect carburetor/fuel ignition system adjustment.See Service section.Air filter blocked. See Service section.Ignition wire to spark plug loose or disconnected.Reconnect.Fuel supply exhausted. Refill the fuel tank.ENGINE LOSES POWERIncorrect carburetor/fuel injection adjustment. SeeService section.Water in fuel supply. Drain and replace fuel.Excessive carbon accumulation in combustionchamber. See Service section.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 47Fuel tank breather vent closed (if so equipped). Openvent.Air filter system blocked. See Service section.OPERATIONAL PROBLEMS.Application: All ModelsALWAyS UTILIZE DIAMOND BLADES INCOMPLIANCE WITh ANSI B7.1, ANSI B7.5 AND/ORLATEST REVISION(S) AND APPLICABLE OShAREGULATIONS. IMPROPER USE OF DIAMONDBLADES CAN RESULT IN PROPERTy DAMAGEAND/OR PERSONAL INJURy.Copies of ANSI B7.1 and B7.5 for review andeducation purposes can be obtained from theAmerican National Standards Institute, 1430Broadway, New York, NY, 10018. Copies of theapplicable OSHA regulations governing the use ofpowered equipment and diamond blades can beobtained from your nearest OSHA office.DIAMOND SEGMENT LOSSa) The Crack Saw is not being held firmly by theoperator, causing the blade to twist or jam in the worksurface. Hold the Crack Saw firmly.b) Overheating due to inadequate supply of coolant (airor water). This is usually accompanied bydiscolorations which appear on the blade blank in thearea of the segment loss. If wet sawing, provideadequate water flow to both sides of the blade.Determine that no water line blockage exists. If drysawing, periodically allow the blade to run out of thesaw cut for up to 20 seconds for every minute ofsawing. This will allow the blade to properly cool beforeresuming sawing operations .c) The blade blank wears thin as a result ofundercutting by abrasive fines generated by thesawing process. The blade blank wears to a knife edgewhich weakens the blank and causes a segment toseparate. If the fines are highly abrasive, wearresistant blanks should be utilized to retard theundercutting phenomenon. Inspect the bladesperiodically during usage for this occurrence. If wetcutting, allow for ample water to flush the fines out ofthe saw cut.d) Improper clamping action by the arbor shaft hubbody and hub flange causes the blade to flutter in thecut or fail to support the blade in proper alignment.Always clean foreign material accumulations from theflange surfaces. Replace the flanges if they becomebent or deformed with factory approved replacementparts only.e) The blade can be too hard for the specific materialbeing sawed, causing excessive dullness and segmentseparation due to impact loads and/or fatigue. Thisoccurrence can also be the direct cause of frictionalheat which can melt the brazing filler material thatsecures the segments to the blade blank. Use a properblade specification for the material being cut. Match thesegment matrix composition to the specific aggregatematerial being sawed.f) The blade rotation while sawing is out of round (notconcentric), resulting in direct impulse loads beingapplied to the segments. Replace worn machinecomponents including bearings and arbor shaft.g) Improper blade rotational speed which producesexcessive pressure on the segments and subsequentfailure of the brazed/welded joint, blade blank orsegment itself. Determine that the blade is beingoperated within the industry recommended RPMspeed range. Engine RPM should be checkedperiodically with an electronic tachometer to ensureproper operational speed for the blade.UNEVEN SEGMENT WEARa) If wet sawing, insufficient water flow to one side ofthe blade which effectively reduces the side clearance.Flush the water system. Determine that water is beingadequately and equally distributed to both sides of theblade.b) Worn machine components. Determine thatmachine components, including bearings, belts andthe arbor shaft are not excessively worn and requiringreplacement. Determine that the engine runs smoothlyto prevent harmonic vibrations which can result in theblade impacting the work surface with impulse typeloads.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 48c) Saw head is misaligned. Periodically check sawhead for squareness in both vertical and horizontalplanes.SEGMENT CRACKSBlade matrix composition is too hard for the materialbeing sawed. Utilize a blade with a softer matrixcomposition.SHORT BLADE SERVICE LIFEa) Utilizing the improper blade for sawing a specificmaterial. Avoid the use of a general purpose blade forsawing a single specific material. General purposeblades are intended to saw a wide range of materials.Since it is unlikely that the machine will saw the properamount of both hard and soft materials proportionatelyat all times, this type of blade is not the mosteconomical method of sawing. Use a blade with thematrix composition designed specifically for thematerial and aggregate being sawed.b) While wet sawing, improper water flow is beingdelivered to both sides of the blade. Determine that allwater hoses are clean and free of any internalblockage. Approximately two to five gallons of waterper minute are required to properly cool a blade.c) Worn machine components. Determine thatmachine components including bearings, belts and thearbor shaft are not excessively worn and requiringreplacement. Determine that the engine runs smoothlyto prevent harmonic vibrations which can result in theblade impacting the work surface with impulse typeloads.d) Loss of power, resulting from improper engine RPMspeed, electric motor voltage or loose V-belts. SeeService section.BLADE WILL NOT SAWa) Blade matrix composition is too hard for the materialbeing sawed. Utilize a blade with a softer matrixcomposition.b) Blade has become dull, probably as a result of ahard matrix composition being utilized to saw a hardmaterial. Dress or sharpen the blade by utilizing it tosaw a softer material to expose new diamonds in thesegments. If continual dressing is required, it wouldindicate that the blade matrix composition is too hardfor the material being sawed.c) Failure to initially break in a new blade on a specificmaterial being cut. Allow the blade to sharpen itself onthe material to be sawed when first placing it on theCrack Saw. This is the proper method to break in a newblade. Do not force the new blade into a cut as this willgenerally aggravate the problem.d) Loss of power, resulting from improper engine RPMspeed, electric motor voltage or loose V-belts. SeeService section.e) When dry sawing, the blade becomes dull as aresult of overheating, allowing the segment rim to"mushroom" or melt. Discontinue usage and contactthe diamond blade manufacturer.BLADE BLANK WARPAGEa) The blade blank has been overheated. While wetsawing, improper water flow is being delivered to bothsides of the blade. Determine that all water hoses areclean and free of any internal blockage.b) The blade blank has been overheated. While drysawing, periodically allow the blade to run out of the cutfor up to 20 seconds for every minute sawing. Thisprocedure will allow the blade to cool in a few secondsand allow the sawing process to proceed. If the bladehas been warped (dark blue color), it may be damagedbeyond repair. A blade in this condition should bediscontinued from use immediately and properlydiscarded.c) The blade blank has been overheated as a result ofspinning on the arbor shaft. Check the arbor shaft, hubbody and hub flange for excessive wear and/ordamage. Properly tighten the arbor shaft nut.d) Unequal flange clamping forces. The hub bodyflange and hub flange must be of the same, identicaldiameter. Always replace any questionable componentwith a factory replacement part only.BLADE WOBBLESa) Worn machine components. Determine thatmachine components including bearings, belts and thearbor shaft are not excessively worn and requiringreplacement. Determine that the engine runs smoothlyCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 49to prevent harmonic vibrations which can result in theblade impacting the work surface with impulse typeloads. Inspect the hub body flange and hub flange formaterial accumulations. Keep all surfaces clean andflat. Always replace any questionable component witha factory replacement part only.b) Improper blade operating speed. Determine that theblade is being operated within the industryrecommended RPM speed range. Engine RPM shouldbe checked periodically with an electronic tachometerto ensure proper operational speed for the blade.c) Blade is bent. Contact the blade manufacturer. Ablade in this condition should be discontinued from useimmediately and properly discarded.BLADE BLANK DAMAGEa) Cracks in the blade blank. Contact the blademanufacturer. A blade in this condition should bediscontinued from use immediately and properlydiscarded.b) Blade blank undercutting. Highly abrasive fines arebeing generated during the sawing process, resultingin an abrading or wearing away of the blank faster thanthe diamond segments. Blades manufactured withwear resistant blanks can be specified from manymanufacturers. Wear resistant blanks may not be theproper solution to the problem. Any blade experiencingthis type of wear problem should be carefully inspectedin shorter intervals to determine proper structuralintegrity. BLADE NOT ROTATING WITH PROPERCONCENTRICITYa) Worn machine components. Determine thatmachine components including bearings, belts and thearbor shaft are not excessively worn and requiringreplacement. Determine that the engine runs smoothlyto prevent harmonic vibrations which can result in theblade impacting the work surface with impulse typeloads.b) Blade arbor hole damaged from previous usage. Ablade in this condition should be discontinued from useimmediately and properly discarded.c) Blade is spinning on the arbor shaft. Check the arborshaft, hub body and hub flange for excessive wearand/or damage. Worn, bent or dirty hub body flangeand hub flange will not allow the blade to be properlytightened on the arbor shaft. Properly tighten the arborshaft nut. Replace any questionable component with afactory replacement part only.d) Blade matrix composition is too hard for the materialbeing sawed. Utilize a blade with a softer matrixcomposition.e) Blade is not properly mounted to the Crack Saw.Determine that the blade is mounted to the properdiameter spindle before tightening the arbor shaft nut.Never depend on the drive pin of the arbor hub toactually drive the blade. The drive pin is simply a safetydevice to prevent the blade from spinning on the arborshaft should the nut become loose.ACCELERATED V-BELT WEARa) Misaligned and/or improperly tensioned pulleys.Readjust pulleys and V-belt. See Service section.b) Worn pulleys. Replace pulleys as required. SeeINSTALLING A REPLACEMENT V-BELT OR PULLEY.c) Improper V-belt. Replace with a name brand BX34series V-belt. Never replace a single belt. Alwaysreplace both V-belts at the same time in matched sets.ACCELERATED BEARING WEAR AND/OR FAILUREa) Misaligned and/or improperly tensioned pulleys.readjust pulleys and V-belts. See Service section.b) Bent arbor shaft. Replace arbor shaft.c) Improper lubrication. See LUBRICATIONREQUIREMENTS.UNEVEN SAWING ACTIONa) Excessive material build-up on the caster wheel facesurface. Remove the material.b) Excessive caster wheel bearing wear. Replace thecaster wheel.c) Excessive axle wear. Replace axle.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 50StorageApplication: All ModelsProper procedure for long term storage of the CrackSaw will protect it against the effects of corrosion anddamage. If the Crack Saw is not to be operated for aperiod of 30 days or more, proceed to store as follows:1) Clean all accumulated foreign material from theCrack Saw utilizing an appropriate safety solvent.Observe all applicable safety precautions for thesolvent.2) Follow the procedure as outlined in the materialsupplied by the engine manufacturer describing longterm storage for the engine.3) Check all visible parts for wear, breakage ordamage. Order any part required to make thenecessary repair. This will avoid a needless delaywhen operating the Crack Saw at next use.4) Apply a dry film lubricant to all exposed metalcomponents to prevent rust.5) Store the Crack Saw inside. If the Crack Saw mustbe stored outside, protect it with a suitable covering.SpecificationsFRAME.STRUCTURE Unitized, welded steel plateDRIVE REDUCTION SYSTEM BX34 Seriesbelt/pulley/spur gear transmissionOVERALL MACHINE WIDTH 27-1/2 inches (699 mm)OVERALL MACHINE LENGTH 52 inches (1321 mm) OPERATOR HANDLE HEIGHT 43 inches (1092 mm)BLADE ROTATION ORIENTATION Downcut asviewed by the operatorVACUUM CLEANER CONNECTION 3 inch (76 mm)diameter GENERAL.DIAMOND BLADE DIAMETER 8 inches (203 mm)nominal ONLY. Do not utilize diamond blades or otherattachments of different diameter other than thatapproved for use with the Crack Saw by themanufacturerAVAILABLE DIAMETER BLADE 1/4 inch (6.4 mm)SAWING WIDTHS 3/8 inch ( 9.5 mm) 1/2 inch (12.7 mm)SPECIAL APPLICATION BLADE 3/4 inch (19 mm)SAWING WIDTHS. CONSULT 1 inch (25.4 mm)THE CUSTOMER SERVICE DEPARTMENT OF GENERALEQUIPMENT COMPANY FOR ADDITIONAL INFORMATION. THERE IS NO CHARGE FOR THIS SERVICE.MAXIMUM STRAIGHT LINE 1-1/2 inches (38 mm)SAWING DEPTH.ARBOR SHAFT DIAMETER 1 inch (25 mm)CS8/E BASIC WEIGHT 275 lbs (125 kg) CS8/G BASIC WEIGHT 290 lbs (132 kg)CS8/GHP BASIC WEIGHT 345 lbs (157 kg)CS8/E ELECTRIC MOTOR 5 hp (37 kw) 3450 RPM,230 VAC, 60 Hz, 3 PhaseCS8/G ENGINE 11 hp (82 kw) or 13 hp (97 kw)nominal, industrial quality, 4 cycle engine, 3450 RPMnominal maximum governed speedCS8/GHP ENGINE 11 hp (82 kw) or 13 hp (97 kw)nominal, industrial quality, 4 cycle engine, 3450 RPMnominal maximum governed speed, converted for usewith Propane. The BTU content of Propane reducesthe effective horsepower by approximately 20 per cent.CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 51CS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 52Left BlankReplacement Parts DiagramsCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 53Operator Handle AssemblyCS8/G Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 54ReferenceNumberPARTNUMBER DESCRIPTION QTY1234567891011121314151617181920212223242526272829303132333435363738CS8-0220CS8-0130SP8-0120SP8-041099502H150812105306000020031200CS8-0240CS8-0420CS8-0190841000001910000117080000CS8-0200150608008106300018060000CS8-02101810001156200000SP8-0160SP8-017040100011151048001810000017100000SP8-0180200682SG24-400053080000CS8-035015040000CS8/GH-037022X18 T-TAPCOV-04111604000017040000Handle, OperatorScrew, CrankKnobScrew, Socket Head, SpecialBearingScrew, Cap, 1/2-13 UNC x 1-1/2”, Plated, Grade 5Nut, Hexagon, Nylock®, 3/8-16 UNC, PlatedPin, Roll, 3/16” x 1-1/2”LeverBearing, Oilite®Hinge, W/BearingsWasher, BellvilleNut, Hexagon, Self-Locking, 5/8-18 UNF, PlatedWasher, Flat, 1/2”, PlatedShaft, Over CenterScrew, Cap, 3/8-16 UNC x 1”, Plated, Grade 5Screw, Cap, 3/8-16 UNC x 3-3/4”, StainlessNut, Hexagon, 3/8-16 UNC, PlatedTube, BearingNut, Hexagon, 5/8-11 UNC, LH, PlatedClamp, Hose, 1-1/4”Boot, RubberBarrel, AdjustingNut, Hexagon, Jam, 5/8-11 UNF, LH, PlatedScrew, Cap, 5/8-11 UNC x 6”, Plated, Grade 5Nut, Hexagon, 5/8-11 UNC, PlatedWasher, Flat, 5/8”, PlatedRod End, MaleWasher, PlasticWasher, Flat 5/8”, Special, PlatedNut, Hexagon, Nylock®, 1/2-13 UNC, PlatedSwitch, On/OffScrew, Cap, 1/4-20 UNC x 5/8”, PlatedHarness, WireT-Tap, 22-18 Gauge WireClamp, PlatedWasher, Lock, 1/4”, PlatedWasher, Flat, 1/4”, Plated11112441142214141112111111112141111111Operator Handle AssemblyCS8/G Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 55Engine Mount AssemblyCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 56ReferenceNumberPARTNUMBER DESCRIPTION QTY12345678910111213141516171819202122232425262728293031323334GX340K1QXC9CS8-0020CS8-0050CS8-0090CS8-0230CS8-0100CS8-004018160011ReferenceCS8-0300CS8-0030SP8-0421SP8-0290CS8-02706304160031040200150620006304120015081000160800001506100053060000CS8-04701806000026040000CS8-0260BX34CS8-040063042000CS8-00701706000085340000CS8-0490SP8-0590Engine, Honda, 11 HPPlate, Engine MountGuard, BeltGuard, BladeBlock, BearingBody, HubPlate, HubNut, Hexagon, 1-14 UNF, LH Thread, PlatedBlade, 8”Bracket, Engine MountShaft, ArborBearing, ModifiedRing, Retaining, ExternalSheave, Arbor ShaftKey, Square, 1/4” x 2”Screw, Set, Cup Point, 1/4-20 UNC x 1/4”Screw, Cap, 3/8-16 UNC x 2-1/2”, Plated, Grade 5Key, Square, 1/4” x 1-1/2”Screw, Cap, 1/2-13 UNC x 1-1/4”, Plated, Grade 5Washer, Lock, 1/2”, PlatedScrew, Cap, 3/8-16 UNC x 1-1/4”, Plated, Grade 5Nut, Hexagon, Nylock®, 3/8-16 UNCScrew, Cap, 3/8-16 UNC x 3-1/2”, Full Thread, Grade 2Nut, Hexagon, 3/8-16 UNC, PlatedPlug, Pipe, 1/4” NPTF, SquareSheave, EngineV-BeltWrench, 1-1/2”Key, Square, 1/4” x 2-1/2”Thrust Plate, V-Belt, TensionWasher, Flat, 3/8”Bushing, MachineryRing, Retaining, InternalFitting, Grease, Straight1111111112121114414437222121114221Engine Mount AssemblyCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 57Frame AssemblyCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 58ReferenceNumberPARTNUMBER DESCRIPTION QTY12345678910111213141516CS8-0010SG24-02601712000022031600CS8-041027040500CS8-0250CS8-0280530600005308000017060000170800006006120015081400CS8-0460SP8-0350Frame, MainWheelWasher, Flat, 3/4”, PlatedPin, Cotter, 3/16” x 2”, PlatedBumper, RubberScrew, Cap, Countersunk, 1/4-20 UNC x 5/8”Wheel, CasterBearing, Pillow BlockNut, Hexagon, Nylock®, 3/8-16 UNC, PlatedNut, Hexagon, Nylock®, 1/2-13 UNC, PlatedWasher, Flat, 3/8”, PlatedWasher, Flat, 1/2”, PlatedScrew, Cap, Socket, 3/8-16 UNC x 1-1/2”, PlatedScrew, Cap, 1/2-13 UNC x 1-3/4”, Plated, Grade 5Pad, Non-SlipCap, Dust Cover1222262248484811Frame AssemblyCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 59Dustpan/Vacuum Port AssemblyCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 60ReferenceNumberPARTNUMBER DESCRIPTION QTY12345CS8-0310CS8-0350564800001508100015080800Shroud, VacuumHose, VacuumClamp, Hose, 3”Screw, Cap, 1/2-13 UNC x 1-1/4”, Plated, Grade 5Screw, Cap, 1/2-13 UNC x 1”, Plated, Grade 511211Dustpan/Vacuum Port AssemblyCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 61Water Cutting Kit AssemblyCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 62ReferenceNumberPARTNUMBER DESCRIPTION QTY1234567SP8-0030CS8-04401506280053060000CS8-032056100000CS8-0330Valve, WaterBlock, ManifoldScrew, Cap, 3/8-16 UNC x 3-1/2”, Plated, Grade 5Nut, Hexagon, Nylock®, 3/8-16 UNC, PlatedAdapter, HoseClamp, Hose, 5/8”Hose, Water1122442Water Cutting Kit AssemblyCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 63Propane Conversion AssemblyCS8 Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 64ReferenceNumberPARTNUMBER DESCRIPTION QTY12345678910111213141516171819202122232425262728295305TB-6CS8-0360SG24-02907141M7141F149F-6-44412-4-6SFC321-063865HC834615040500VFF30-2-417060000TB-2-60650-0021806000015061000CS8-50605610000033SBAF4-6611SB2247-4-4S501-12350-G506-0092F-2562F-158Cylinder, PropaneBracket, Propane CylinderMount, Propane TankBracket, Propane ValvesAdapaterConnectorFitting, 90°Fitting, HP StraightHoseValve, ReliefFittingScrew, Cap, 1/4-20 UNC x 5/8”, PlatedFuelock, Filter, VacuumWasher, Flat, 3/8”, PlatedToggleCap, VacuumNut, Hex, 3/8-16 UNC, PlatedScrew, Hex Head, 3/8-16 UNC x 1-1/4”, PlatedDecal, Propane StartClamp, Hose, 5/8”Hose NippleBackcheck, VacuumNipple, HoseElbowHose, FuelRegulator, FuelHose, VacuumSpudFitting11111111111416126612111111111Propane Conversion AssemblyCS8 Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 65DecalsCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 66ReferenceNumberPARTNUMBER DESCRIPTION QTY1234567891011GECD-5040SP8-5050SP8-5040SP8-5030SP8-5061CS8-5050CS8-5030CS8-5020SG24-5072CS8-5070SP8-5020Decal, GeneralDecal, WarningDecal, WarningDecal, WarningDecal, GreaseDecal, WarningDecal, OperationDecal, WarningDecal, AssistanceDecal, Shut-OffDecal, Depth Control12121212111Replacement DecalsCS8 Series Crack SawCS8 RANDOM CRACK SAWFORM GOM5229601, VERSION 1.2 67