MORLEY M48 User manual

ORLEY
EQUIPMENT CO
M48
HYUNDAI
OWNERS
MANUAL
SERIAL #:
ENGINE #:

WARNING
• Ifoperatedimproperly,thismachinemaycauseseriousinjury.
• Donotwearlooseclothingwhenoperatingthismachineasitmay
becomeentangledintheequipment.
• Stayclearofallmovingpartswhenthemachineisrunning.
• DONOTworkonthismachinewhiletheengineisrunningandNOT
properlysecured.
• ALWAYSwearsafetyglasses,soundprotection(earplugs),hand
protection(gloves),andsteel-toedbootswhenoperatingthismachine.
• NEVERstandinwaterwhileoperatingthismachine(ELECTRIC
MODEL).
• ALWAYSuseproperlygroundedpowercords(ELECTRICMODEL).
• PowercordsshouldALWAYSbetheproperwiregaugeforeach
particularapplication(ELECTRICMODEL).
• ALLextensioncordsshouldbepluggedintoa“groundfault
interrupter”(ELECTRICMODEL).
• NEVERuseextensioncordsthatareinanywaydamaged,frayedor
cut(ELECTRICMODEL).
• ALWAYSusethepropercuttingRPMasspecificiedbyyourblade
manufacturer.
• ALWAYSshutoffthemachinebeforechangingtheblade(UNPLUG
ELECTRICMODELbeforechangingtheblade).
• InsureproperpositionandsecurityofALLsafetyguardsbefore
operatingthismachine.
• ALWAYSinspectthemachinebeforeuseforsafeoperation.
• FIREHAZARD!Inspectforanyleakingfluids(gas,oilandetc.)
operationofthismachine

• DONOTattemptofoff-loadanypieceofequipmentonunevengroundof
anydegreeofslope.DONOTleaveequipmentunattendedonuneven
ground.Injuryordeathmayoccur.
THIS EQUIPMENT SHOULD NOT BE OPERATED BY ANYONE UNDER
THE AGE OF 18.
• DONOTjump-startadeadbatteryonthismachine.Theprocessof
jump-startingadischarged(dead)batterycan,undercertainconditions,result
inabatteryexplosionfromtheignitionofhydrogengas,resultingininjury
ordeath.
WARNING Continued
WARRANTY:
MorleyEquipmentCompanyWarrantsthatatthetimeofshipment,theproduct
manufacturedbyMorleyEquipmentCompanyandsoldhereundershallbefreefrom
defectsinmaterialandworkmanship.
WARRANTY ADJUSTMENTS:
MorleyEquipmentCompanyagreestorepairorfurnishanyfaultycomponentwithin30-
daysfromdateofpurchaseprovidedthemachineisoperatedandmaintainedin
accordancewithMorleyEquipmentCompanyOwnersandEngineManualsand
OperatingInstructions.
IfexaminationsbyMorleyEquipmentCompanyprovesadefectwithinWarranty,receipt
verifyingpurchasedateandserialnumbersarerequiredtoobtainAdjustment.Oneyear
Warrantyonmajorcomponents(suchasengine,drivemotors,hydraulicpump,
hydraulicmotorandetc.)withanauthorizedservicefacility.SeeOwnersManualfor
Warrantyfromthemanufacturerofthatproduct.
Noproductwillbeacceptedforreturnorreplacementwithoutpriorauthorizationby
MorleyEquipmentCompany.Productsreturnedareaddressedto:
Morley Equipment Company, 41161 Sandalwood Circle, Murrieta, CA 92562:
[phone].
EXCLUSIONS FROM WARRANTY:
ThisWarrantydoesnotextendtoanyproductsuppliedbyMorleyEquipmentCompany
whichhasbeensubjectedtomisuse,neglect,accident,improperinstallationorusedin
violationofinstructionsprovidedbyMorleyEquipmentCompany.
LIMITED WARRANTY

M48 SAW INFORMATION
1. ThisManualprovidesthebasicinstructionsfortheoperationandmaintenanceof
theM48concretesaw.AndEngineManualisalsoprovidewitheachsaw.
2. M48 - WATERCOOLED:
ENGINE: Hyundai ZPP 416 - Gas
Drive Unit: Hydrostatic Transmission
Water Pump: Self-priming Electric (Optional)
Spindle: 1-7/16”
Arbor Size: 1” with 1/4” Keys
Blade Capacity: 14” to 36” Diameter
Depth Control: Hydraulic Raise/Lower
Depth Gauge and Locking Stop
Fuel Capacity: 5-Gallons
Weight: Single Speed: 1,040 Lbs, 3-Speed: 1,130 Lbs
Length: 43”
Width: 29” w/Quick Detach Spindle
Height: 44”
OPTIONAL EQUIPMENT
1. 3-Speed Gearbox
2. Night Light
3. Bladeguards - 24”, 30”, and 36”
4. Electric Water Pump
3. Thenewmachinewastest-runbeforeleavingMorleyEquipmentCompany,
however,theengineshouldbecheckedwiththeEngineManualsothatthe
correctroutineisfollowedatalltimes.Checkallfluidlevels.Thisisvery
importantduringtheinitialrunning-inoftheengineasspecifiedintheEngine
Manual.
4. LUBRICATION/SERVICE CHART
ITEM
HydrostaticTransmission(F/R)
AirFilter
HydraulicPump(R/L)
SpindleBearings
PivotAxle
FrontWheels
Radiator
CHECK
Monthly
Weekly
Monthly
Daily
Weekly
Weekly
Daily
LUBRICANT
20W-50MotorOil
Serviceasrequired
ATF
Grease
Grease
Grease
Squirtdebrisoutof
coolingfins

5. Toadjustorreplacethebelts,loosenthe1/2”“pinch”bolts,oneoneitherside
atthefrontofthemotorbaseplate,andthetwo5/8-inchboltsthatrunverticalatthe
frontotthemotorplate.Thisallowsthemotortoberaisedorlowered,looseningthe
beltsforreplacementortensioning.Thenraisethemotorandtightenthebolts
afterbeltreplacementortoadjusttension.Itisimportantthatthetensionisjust
enoughtodrivewithoutslipping.Tootightshortensbearinglife,toolooseshortens
beltlife(SpindleshaftBelts-(7)3VX400,SingleSpeed&3-Speed.)
CONTROL OPERATING INSTRUCTIONS
1. WATER SUPPLY: Connectthewatersupplytothe“inlethose(1/2”),”openthe
watervalveandmakesurethat“outlet(1/4”),”hosesmountedinthe
bladeguardarefreeofobstructions.Blowoutthewaterlinesbeforeoperationin
freezingconditions.
2. RAISE/LOWER: BypullingbacktheRaise/Lowerleveramomemtaryswitch
activatesanelectric-over-hydraulicpumptoraisethesaw.Pushtheleverfowardto
lowerthesaw.Youcancontroltheloweringspeedbyopeningthevalvegradually.
Foradjustingthehandleassembly,seeaccompanyinginstruction.
3. SPEED CONTROL: TheForward/Reverseleverdeterminesforwardandreverse
speeds,witha“neutral”dynamicbrakepositioninbetween.Bypushingthespeed
controlleverfoward,thesawwillmoveforwardatvariablespeeds,pullingthelever
backdoesthesameinreverse.
4. BLADE FITTING: Raisethesawtoaccommodateyourchoiceofblades-14”to30”.
Liftoffthebladeguardwithengineoff.Removethespindlenutwiththespindlenut
wrenchprovidewiththesawandthentheouterbladecollar.Inspectbothcollarsso
theywillseatflushwiththeblade.Placebladeonspindleshaftandalignwithcollarpinin
innercollar,nowreplaceoutercollarandspindlenut-tightenbystrikingspindlenutwrench
withprovidedhammerandfinally,replacebladeguard.
5. STARTING THE ENGINE: ThisshouldbedoneasexplainedintheEngine
Manual.
6. POSITIONING THE SAW: Thesawmaybemaneuveredinseveralways.Position
thehandlebarstosuittheoperator’sleverage(Note:thisisarear-pivotsaw).The
independentdrivemotors,thefunctionasadifferential,allowthesawtoberotatedby
liftingthefrontwheelsoffthegroundbypushingdownonthehandlebarsandrotating

7. CUTTING: Layoutthecutsusingachalklineorstringandpaint.Usethe
pointerguideasyousawcut“gunsite.”Bringtheenginetotheblademanufacturer’s
recommendedRPM.Positionthesawtoinitiatethecut.Whenalignedandpositioned,
turn-onthewaterandlowerthesawtodesiredcutdepth,thenmovethesawforwardto
acomfortablecuttingspeed-don’t“labor”theblade.Wateramountisanacquired
science-askyourblademanufacturerforrecommedantions.Readingtheslurryisyour
keytocost-effectivecutting-justtherightamountofwaterisneededforcuttingspeed
andbladelife(ablade’saccumulatedinch-feetcut).Itisrecommendedtostep-cut-
takeseveralpassestoreachdesireddepth-thisalsobenefitsbladelife.Oncethe
chalked-outcuthasbeencompleted,returntheForward/Reverselevertothe“neutral”
positionandusingtheRaise/Lowerlever,raisethesawoutofthecut.Ifstep-cutting,
returnthesawtotheoriginalinsertionpointandlowerthebladetothesecondarydepth
andrepeatthecut,thenraisethebladeasbeforeandpositionthesawforthenextcut.
8. CLEANING: Theentiresawshouldbethoroughlywashedweeklyorasrequired.
Usecautiontopreventwaterfromassociationwiththefueltandandelectricalsystem.
WD40workswellasawaterdispersant.Besuretosquirtanydebris-dust,slurry
andetc.-outoftheradiator’scoolingfins.
9. STORAGE: Alwayslubricatethesawaftercleaning.
10. CALIBRATION: Alwayscheckalignment.Thespindleshaftandrearaxlesmustbe
alignedtoinsurethesawtravelsstraightandtheblademovesparalleltotherear
wheels.
11. REPLACEMENT PARTS: Allreplacementpartsmustbeorderedfrom
MorleyEquipmentCompanytoeffectWarranty.AlwayssupplyModelandSerial
Numberwhenorderingparts.
12. QUESTIONS AND CONCERNS: Shouldyouhaveanyquestionsrelativetothe
operationorservicingyourequipment,donothesitatetocontactMorley Equipment
Companyat[phone];orEmailusat[email protected].APartsList
forthesawisalsoavailableon-lineatwww.morleysaws.com
CONTROL OPERATING INSTRUCTIONS Continued:
thesawontherearwheelsinthedesireddirection,leftorright,andpositioningforthe
nextcut.Thesawmayalsobepositionedbyusingthe“wheel-borrow”approach-lift
therearwheelsandrotatetothedesiredpositionusingthefrontwheelstopivotthe
saw.

M48 PARTS LIST
SPINDLESHAFT ASSEMBLY
PARTS# REQUIRED DESCRIPTION
1100-48 1
1101-48 2
1115-48 2
1116-48 2
1104-48 1
1105-48 1
1106-48 1
1107-48 1
1108-48 1
1109-48 2
1110-48 6
1118-48 1
1119-48 1
Spindleshaft
Pillow-blocking Bearing
Inner Collar
Outer Collar
Left-hand Nut
Right-hand Nut
Sheave
Bushing
Key - 3/8”
Key - 1/4”
3VX 425 Belt
L-hand Spindle Stud
R-hand Spindle Stud
2100-48 1 Weldment
2112-48 2 Axle - 1”
3002-48 2 Wheel - 6x2”
5004-48 2 Collar - 1”
2104-48 2 Pillow-block Bearing - 1”
2105-48 1 Pin - 5/8”x3.5”
2106-48 1 Depth Gauge, Cable, and Spring
2114-48 1 Pin - 5/8”x3”
3100-48 1
3101-48 1
3102-48 1
3103-48 1
3106-48 1
Pump Motor
Flow Control Valve
Hydraulic Cylinder
Raise/Lower Assembly
Solenoid
FRONT AXLE ASSEMBLY
HYDRAULIC RAISE/LOWER ASSEMBLY

HYDROSTATIC DRIVE ASSEMBLY
PART# REQUIRED DESCRIPTION
4100-48 1
4101-48 2
4102-48 1
4103-48 2
3001-48 2
4105-48 1
4106-48 1
4107-48 1
4201-48 1
4109-48 1
4110-48 2
4111-48 1
4112-48 1
4113-48 1
Pump
Drive Motor
Traction Manifold
Wheel Hub
Wheel - 10”x3”
Filter Assembly
Filter
Reservoir - Plastic
Forward/Reverse
Lever Assembly
Cable
Drive Cable 33"
Hydrostatic Pump Belt – 4L3400 or A-32
Wheel Motor Bracket
Hydrostatic Drive Pump Bracket
5100-48 1
5101-48 1
5102-48 2
5103-48 2
5104-48 1
Weldment
3” Pointer Wheel
Delrin Bushing
Cable
Lift Cable
6100-48 1
6101-48 1
6102-48 1
6103-48 1
6105-48 1
6106-48 1
6107-48 1
3022-48 1
3026-48 2
6110-48 2
6118-48 1
2111-48 1
2119-48 1
Mainframe
Console
Belt Guard - Left Side
Belt Guard - Right Side
Air Intake - Rear
Air Exhaust - Left Side
Access Panel - Electrical
Handlebar
Locking T - Handle
Fuel Tank
Gas Cap
Lower Depth Stop Rod
Assembly
Upper Depth Stop Rod
Assembly
POINTER ASSEMBLY
FRAME CONSOLE

FRAME CONSOLE Continued:
PART# REQUIRED DESCRIPTION
6115-48 2 Fuel Tank Hold-down Strap
HYUN-48 1
7101-48 2
7102-48 1
7102-48-A 2
7102-48-B 1
7102-D 1
7102-E-M48 1
7103-48 1
7104-48 2
4183-48 2
7106-48 1
7107-48 1
7108-48 1
7109-48 1
7124-48 1
6117-48 1
6114-48 1
Hyundai 1.6-Liter, Gas
Bellhousing - Inner/Outer
Output Shaft/Drive Assembly
Bearing - Output/Drive Assembly
Shaft - Output/Drive Assembly
BoWex Male Coupler
BoWex Female Coupler
Air Filter
Air Filter Element
Hose - 90-Degree Elbow - 2”
Hose Coupler
Air Filter Bracket
Exhaust/Catalytic Converter
Exhaust/Catalytic Converter Bracket
Fuel Pressure Regulator
Fuel Pump
Fuel Filter
8100-48 1 Water Distribution Block w/Hose Fittings
8181-48 2 Outlet Water Hose - 1/4”
8102-48 1 Inlet Water Hose - 1/2”
8103-48 1 Water Valve
8104-48 1 Mud Flap
8105-48 1 20” Bladeguard
8106-48 1 26” Bladeguard
8107-48 1 30” Bladeguard
8108-48 1 36” Bladeguard
ENGINE
BLADEGUARD ASSEMBLY
7711-48 1Radiator
3009-48 1 Fan Stroud
7774-48 1 Electric Fan
7719-48 1 Fan Relay Harness
COOLING SYSTEM

CONSOLE
PART# REQUIRED DESCRIPTION
9100-48 1 Tach/Engine Vitals Gauge
9101-48 1 Emergency Shutoff Switch
9102-48 1 Push-Bottom Start Switch
9103-48 1 Engine Speed Control Switch
9104-48 1 Engine Service Indicator Light
9105-48 1 Upper Console Sticker
9106-48 1 Lower Console Sticker
RAISE
FLOW CONTROL
VALVE
Justinsidetherearaccess
panelontherightsideisa
needlevalvethatallowsyouto
adjustthraisingspeed
impartedbytheRaise/Lower
Lever.Yoursawcomeswiththe
raisespeedpre-setatthe
factory.Thisvalveallowsyouto
resetthespeedtosuityour
needs

DRIVE BELTS FAN BELT
M44D KUBOTA
Single Speed 3VX425(6) 3VX475 3VX315
w/3-Speed 3VX400(6) 3VX475 3VX315
M48 HYUNDAI
Single Speed NONE 4L3400
w/3 Speed 3VX 425 (6) NONE 4L3400
M44D/M48 3-SPEED GEARBOX OPERATION
GEAR SELECTION
Tochangegears,move
thegearselectorlever
whileslightlyrotatingthe
spindleshaft.Thisallows
thegearstomeshprop-
erly.Neverchangegears
withtheenginerunning.
TheCharttotheleft,lists
thespindleshaftspeeds
ineachofthethreegears
–1stGear,LowerGear–
2.25:1;2ndGear–1.5:1;
and3rdGear,HighGear
– 1:1.
LUBRICATION:
85W-140Multi-Purpose
GearOilortheequiva-
lent.
BELT GUIDE
SPINDLESHAFT SPEED W/3 SPEED GEARBOX
HYDROSTATIC
PUMP BELT
M44D KUBOTA/M48 HYUNDAI
ENGINERPM 2600 2700 2800 2900 3000
1stGEAR(LowGear) 1155 1200 1244 1289 1333
2ndGEAR 1733 1800 1867 1933 2000
3rdGEAR(HighGear) 2600 2700 2800 2900 3000
*Alwaysdefertotheblademanufacturer’ssuggestedrpmforsafetyandbestbladeperformance.
SPINDLESHAFT SPEED – rpm*
Optimum
1st Gear (Low)
2.25:1
2nd Gear (Low)
1.5:1
3rd Gear (High)
1:1

RAISE/LOWER
VALVE
ADJUSTMENT
From time to time your
Raise/Lower Assembly may
need some minor
adjustments. If your saw
creeps down when the R/L
Lever is returned to its
“neutral” position after being
raised, the needle valve is not
closing completely. The
following adjustment is an
easy x.
Needle valves are known to take a “set” after continued use, meaning the stops
(open/close) change slightly so the R/L Lever (C) doesn’t completely close the
valve or open the valve when the Lever reaches its stops. Opening the valve to
lower the saw is not the issue, its the valve not closing completely that presents
the problem.
By loosening this 7/16” nut (A) you can rotate the adjusting arm (B) to close the
needle valve. Once that adjustment has been made, tighten the nut. Now, when
the R/L Lever is pulled all the way back as the saw is raised and a spring then
returns the Lever back to its original “neutral” position, the saw will no longer
creep down.