MULTIQUIP FCG1 SERIES User manual

© COPYRIGHT 2004, MULTIQUIP INC.
OPERATION & PARTS MANUAL
CONCRETE SAW
FCG1 SERIES
Revision #2 (03/10/04)
MODEL #
SERIAL #
P/N 35261
Atlanta • Boise • Newark •
Montreal,Canada • Manchester,UK
RioDeJaniero, BR • Puebla, MX
MULTIQUIP (UK)
HANOVER MILL
FITZROY STREET
ASHTON-UNDER-LYNE
LANCASHIRE, OL7 OTL
UNITED KINGDOM
PH. 0161-339-2223
FAX. [phone]
E-MAIL:[email protected]
www.multiquip.com
EXPORT VERSION
ORIGINAL INSTRUCTIONS

FCG1 CONCRETE SAW — OPERATION & PARTS MANUAL — REV. #2 (03/10/04) — PAGE 3
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER
ON-HAND WHEN CALLING
UNITED STATES
MULTIQUIP CORPORATE OFFICE
18910WilmingtonAve. Tel. [phone]
Carson,CA90746 Fax [phone]
Contact:[email protected]
MEXICO
MQ CIPSA
Carr.Fed.Mexico-PueblaKM126.5 Tel. [phone]
Momoxpan,Cholula,Puebla72760Mexico Fax [phone]
Contact:[email protected]
UNITED KINGDOM
MULTIQUIP (UK) LIMITED HEAD OFFICE
HanoverMill,FitzroyStreet, Tel. [phone]
Ashton-under-Lyne, Fax [phone]
Lancashire OL7 0TL
Contact:[email protected]
CANADA
MULTIQUIP
4110IndustrielBoul. Tel. [phone]
Laval,Quebec, CanadaH7L 6V3 Fax [phone]
Contact:[email protected]
BRAZIL
MULTIQUIP
Av.EvandroLinse Silva,840-grupo505 Tel. [phone]
BarradeTijuca -Rio deJaneiro Fax [phone]
RJCEP22631-470
Contact:[e-mail],[e-mail]
Visitour websiteat:www.multiquip.com
Your LocalDealer is:

PAGE 4 — FCG1 CONCRETE SAW— OPERATION & PARTS MANUAL — REV. #2 (03/10/04)
FCG1 CONCRETE SAW— TABLE OF CONTENTS
NOTE
Specificationsand
part numbersare
subjectto change
withoutnotice.
Honda GX200QXC9 Engine MULTIQUIP— FCG1 CONCRETE
SAW
Here's How To Get Help............................................ 3
Table Of Contents ..................................................... 4
Specifications ............................................................ 5
Dimensions ............................................................... 6
Safety Message Alert Symbols..............................7-8
Rules For Safe Operation ....................................9-11
Operation And Safety Decals.................................. 12
General Information................................................ 13
Components.......................................................14-15
Basic Engine ........................................................... 16
Guards, Covers and V-Belts...............................17-18
Blades ..................................................................... 19
Blade Placement ................................................20-22
Pre-Inspection......................................................... 23
Operation ...........................................................24-27
Maintenance ......................................................28-29
Troubleshooting (Saw) ............................................ 30
Troubleshooting (Engine)...................................31-32
Explanation Of Codes In Remarks Column ............ 34
Suggested Spare Parts........................................... 35
Component Drawings
Decal Locator.....................................................36-37
Guards Assembly...............................................38-39
Guides Assembly ...............................................40-41
Undercarriage Assembly ...................................42-43
Handle & Depth Adjuster Assembly ...................44-45
Engine & Blade Drive Assembly.........................46-47
Air Cleaner Assembly.........................................48-49
Camshaft Assembly ...........................................50-51
Carburetor Assembly .........................................52-53
Control Assembly ............................................... 54-55
Crankcase Cover Assembly...............................56-57
Crankshaft Assembly .........................................58-59
Cylinder Barrel Assembly...................................60-61
Cylinder Head Assembly....................................62-63
Fan Cover Assembly..........................................64-65
Flywheel Assembly ...........................................66-67
Fuel Tank Assembly ...........................................68-69
Ignition Assembly ............................................... 70-71
Muffler Assembly ...............................................72-73
Piston Assembly.................................................74-75
Recoil Starter Assembly.....................................76-77
Gasket Kit Assembly ............................................... 79
Labels Assembly ................................................80-81
Terms and Conditions of Sale................................. 82

FCG1 CONCRETE SAW — OPERATION & PARTS MANUAL — REV. #2 (03/10/04) — PAGE 5
FCG1 CONCRETE SAW— SPECIFICATIONS
* Nominal Mass: Mass without blade, all fluid tanks empty, any optional parts removed.
** Maximum Operating Mass: Includes blade, all fluid tanks full, any necessary components installed.
*** Hand/Arm Vibration (at handle) results with SFCG1 Saw cutting cured concrete at a depth of 12.7 mm (1/2") with a
254 mm (10") blade at FULL THROTTLE.
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ekortSXeroB mm45xmm86 ).ni1.2X.ni7.2( mm06xmm76 ).ni63.2X.ni46.2(
tnemecalpsiD).ni-uc0.21(cc691).ni-uc78.21(cc112
tuptuOxaM .M.P.R0063/Wk8.4 ).P.H4.6( .M.P.R0004/Wk1.5 ).P.H0.7(
yticapaCknaTleuF sretiL6.3.xorppA )snollaG.S.U59.0( sretiL6.3.xorppA )snollaG.S.U59.0(
leuF enilosaGelibomotuAdedaelnU rengihroenatcO68 enilosaGelibomotuAdedaelnU rengihroenatcO68
yticapaCliOebuL)tqSU36.0(retil06.0)tqSU426.0(retil06.0
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dohteMgnitratStratSlioceRtratSlioceR
noisnemiD )HxWxL( mm533X673X313 ).ni2.31X8.41x3.21( mm533X663X113 ).ni91.31X4.41x42.21(
yrD thgieWteN ).sbl3.53(gK61).sbl82.53(gK61
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)mm(.niyticapaCedalB ).nI01(mm452
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2

PAGE 6 — FCG1 CONCRETE SAW— OPERATION & PARTS MANUAL — REV. #2 (03/10/04)
FCG1 CONCRETE SAW— DIMENSIONS
Figure 1. FCG1 Concrete Saw Dimensions
Side View
Front View
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A
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)HxWxL(noisnemiDdetarC ).nI32x.nI5.31x.nI5.43(MC4.85xMC3.43xMC6.78

FCG1 CONCRETE SAW — OPERATION & PARTS MANUAL — REV. #2 (03/10/04) — PAGE 7
Safety precautions should be followed at all times when
operating this equipment. Failure to read, understand and
comply with the Safety Messages and Operating Instructions
could result in injury to yourself and others.
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
This Owner's Manual has been
developedto provideinstructions
forthe safeandefficient
operationof theFCG1 Concrete
Saw. For engine maintenance
information,please refertothe
enginemanufacturer's
instructionsfor datarelativeto its
safeoperation.
Before using this Concrete Saw, ensure that the operating
individual has read, understands, and complies with all
instructions in this manual.
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
theoperator, and arepreceded by one ofthree words: DANGER,
WARNING, or CAUTION.
You WILL be
KILLED or SERIOUSLY INJURED
if you DO NOT follow these directions.
You CAN be KILLED or
SERIOUSLY INJURED if
you DO NOT follow these directions.
You CAN be
INJURED if you DO NOT follow
these directions.
HAZARD SYMBOLS
Engine exhaust gases contain poisonous
carbon monoxide. This gas is colorless and
odorless, and can cause death if inhaled.
NEVER operate this equipment in a confined
area or enclosed structure that does not
provide ample free flow air.
Gasoline is extremely flammable, and its
vapors can cause an explosion if ignited.
DO NOT start the engine near spilled fuel or
combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or
sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
use fuel as a cleaning agent.
Explosive Fuel
Burn Hazards
Enginecomponentscangenerateextremeheat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. NEVER operate the engine with
heat shields or heat guards removed.
Rotating Parts
NEVER operate equipment with covers, or
guards removed. Keep fingers, hands, hair
and clothing away from all moving parts to
prevent injury.
NOTE
CAUTICAUTI
CAUTICAUTI
CAUTION
DANGERDANGER
DANGERDANGER
DANGER
WARNINGWARNING
WARNINGWARNING
WARNING
Potentialhazards associatedwithFCG1 Concrete Sawoperation
willbe referenced withHazardSymbols which appearthroughout
this manual, and will be referenced in conjunction with Safety
Message Alert Symbols.
FCG1 CONCRETE SAW— SAFETY MESSAGE ALERT SYMBOLS
Lethal Exhaust Gases

PAGE 8 — FCG1 CONCRETE SAW— OPERATION & PARTS MANUAL — REV. #2 (03/10/04)
FCG1 CONCRETE SAW— SAFETY MESSAGE ALERT SYMBOLS
Accidental Starting
ALWAYS place the ON/OFF switch in the OFF
position, when the saw is not in use.
Over Speed Conditions
NEVER tamperwith the factorysettingsof the
enginegovernor. Personalinjury and damage
to the engine or equipment can result if
operating in speed ranges above maximum
allowable.
Guards and Covers In Place
NEVER operate the saw without blade guards
andcoversin place. Adhere tosafety guidelines
or other applicable local regulations.
Respiratory Hazard
ALWAYS wear approved respiratory
protection.
ALWAYS wear approved eye and hearing
protection.
Sight and Hearing hazard
Equipment Damage Messages
Other important messages are provided throughout this manual
to help prevent damage to your slab saw, other property, or the
surrounding environment.
This concret/asphalt saw, other property, or
the surrounding environment could be
damaged if you do not follow instructions.
CAUTICAUTI
CAUTICAUTI
CAUTION

FCG1 CONCRETE SAW — OPERATION & PARTS MANUAL — REV. #2 (03/10/04) — PAGE 9
FCG1 CONCRETE SAW— RULES FOR SAFE OPERATION
The following safety guidelines should always be used when
operatingthe FCG1Saw.
SAFETY
■ DO NOT operateorservicethisequipment
before reading this entire manual. The
manualmustbekeptavailableandaccessible
totheoperator.
■ Thisequipmentshould notbeoperatedby personsunderthe
minimumstatutory agelimit.
■ ALWAYS useextremecautionwhenworkingwithflammable
liquids. When refueling, STOP the engine and allow it to
cool.
■ NEVER operate the saw in an
explosive atmosphere where fumes
are present, or near combustible
materials. An explosion or fire could
resultin severe
bodily harm or even
death.
■ NEVER touch the hot exhaust manifold,
muffler or cylinder.Allowthese parts tocool
beforeservicingthesaw.
■ The engine of this saw requires an adequate free flow of
cooling air. NEVER operate the saw in any enclosed or
narrow area where free flow
of the air is restricted. If the
air flow is restricted it will
causeseriousdamagetothe
saw'sengineandmaycause
injury to people. Remember
the saw's engine gives off
DEADLY carbon monoxide
gas.
■ HighTemperatures –Allowtheenginetocoolbeforeadding
fuel or performing service and maintenance functions.
Contactwith
hot! components cancause seriousburns.
■ ALWAYS refuelin awell-ventilatedarea, awayfrom sparks
andopen flames.
RULES FOR SAFE OPERATION
■ ALWAYS check the saw for loosened hardware such as
nutsand boltsbeforestarting.
■ Replacenameplate,operationand safetydecalswhenthey
becomedifficulttoread.
■ NEVER use accessories or attachments which are not
recommended by Multiquip for this equipment. Damage to
theequipment and/orinjury tousermay result.
■ Manufacturerdoesnotassumeresponsibility foranyaccident
due to equipment modifications. Unauthorized equipment
modification will void all warranties. Any modification which
could lead to a change in the original characteristics of the
machineshouldbemade onlybythe manufacturerwho shall
confirm that the machine is in conformity with appropriate
safetyregulations.
WARNINGWARNING
WARNINGWARNING
WARNING
Failuretofollowinstructionsinthismanualmayleadtoserious
injury or even death! This equipment is to be operated by
trained and qualified personnel only! This equipment is for
industrial useonly.
■ NEVER smoke around or near the
machine. Fire or explosion could result
from
fuel vapors , or if fuel is spilled on a
hot! engine.
■ Topping-offto fillerportisdangerous,asittends tospillfuel.
■ NEVER usefuel asa cleaningagent.
■ NEVER operate this equipment when not feeling well due to
fatigue, illnessor takingmedicine.
■ NEVER operate the saw under the influence or drugs or
alcohol.
■ NEVER operate the saw without proper protective clothing,
shatterproof glasses, steel-toed boots and other protective
devicesrequired forthe job.
■ NEVER use this machine for any purpose other than those
describedinthismanual.

PAGE 10 — FCG1 CONCRETE SAW— OPERATION & PARTS MANUAL — REV. #2 (03/10/04)
FCG1 CONCRETE SAW— RULES FOR SAFE OPERATION
General Safety
■ ALWAYS read, understand, and follow procedures in
Operator'sManual beforeattemptingtooperateequipment.
■ ALWAYS besure theoperatoris familiarwithpropersafety
precautionsand operatingtechniquesbeforeusing thesaw.
■ NEVER leave the machine unattended while running.
■ Apply the brakes when leaving or when using on a slope.
■ Maintain this equipment in a safe operating condition at all
times.
■ ALWAYS stopthe enginebeforeservicing,adding fueland
oil.
■ NEVER run the engine without the air filter. Severe engine
damagecould occur.
■ ALWAYS serviceaircleanerfrequentlytopreventcarburetor
malfunction.
■ AVOID wearingjewelryor loosefittingclothingthatmaysnag
on the controls or moving parts, this can cause a serious
injury.
■ ALWAYS keepclearof rotating or moving parts while the
sawisin operation.
■ No one other than the operator is to be in the working area
when the saw is in operation.
■ Always observe all applicable compulsory regulations
relevanttoenvironmentalprotection,especially, fuelstorage,
the handling of hazardous substances, and the wearing of
protective clothing and equipment. Instruct the user as
necessary, or, as the user, request this information and
training.
■ ALWAYS storeequipmentproperlywhenitisnotbeingused.
Equipment should be stored in a clean, dry location out of
thereach ofchildren.
Diamond Blade Safety
■ Use appropriate steel centered diamond blades
manufacturedforuse onconcrete saws. Seefurther blade
informationon pages21 through23.
■ ALWAYS keep thework areawellorganized.
■ ALWAYS Clear thecutting areaof anydebris,tools,etc.that
wouldconstitutea hazardwhile thesaw isin operation.
ALWAYS inspect diamond blades
before each use. The blade should
exhibit nocracks,dings, orflawsinthe
steelcentered coreand/orrim. Center
(arbor) hole must be undamaged and
true. All damaged blades must be
discarded.
ALWAYS check to make sure that the
operatingarea isclearbefore startingthe
engine.
WARNINGWARNING
WARNINGWARNING
WARNING
■ Examinebladeflanges fordamage andexcessivewear.
■ Ensurethecleanlinessof thebladebeforeblade isinstalled.
Blade should fit snugly on the shaft and against the inside/
outsideblade flanges.
■ Ensurethe bladeis markedwithan operatingspeedgreater
thanthe spindlespeed ofthe saw.
WARNINGWARNING
WARNINGWARNING
WARNING
■ ALWAYS keep blade guards in place. Exposure of the
diamondblade mustnot exceed180 degrees.
■ Ensure that the diamond blade does not come into contact
with the ground or surface during transportation. DO NOT
dropthe diamondblade onground orsurface.
■ The engine governor is set to regulate maximum engine
speedin ano-load condition. Donottamper withtheengine
governortoincreasethespeed. Increasingtheenginespeed
could allow the maximum rated spindle speed to be
exceeded,creating anunsafe condition.
■ Ensure that the blade is mounted for proper operating
direction.(See Figure12)
■ Adhere to the Blade Manufacturer's recommendations on
handling,storage, andsafe usageof blades.
Onlycutthematerialthatisspecifiedforthediamondblade.
Read the specifications of the diamond blade to ensure
thepropertoolhasbeenmatchedtothematerialbeingcut.
Thesawhasbeenengineeredfor DRY CUTTING. Ensure
a DRY CUTTING blade is being used.
WARNINGWARNING
WARNINGWARNING
WARNING

FCG1 CONCRETE SAW — OPERATION & PARTS MANUAL — REV. #2 (03/10/04) — PAGE 11
FCG1 CONCRETE SAW— RULES FOR SAFE OPERATION
Maintenance Safety
zz
zz
z
NEVER lubricate components or attempt service on a
runningmachine.
zz
zz
z ALWAYS allow the machine a proper amount of time to
coolbefore servicing.
zz
zz
z Keepthe machineryin properrunning condition.
zz
zz
z
Fix damage to the machine immediately and ALWAYS
replacebroken parts.
zz
zz
z Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, fuel and
fuelfilters.
zz
zz
z DO NOT use food or plastic containers to dispose of
hazardouswaste.
Emergencies
zz
zz
z
ALWAYS knowthelocationof
thenearest
fire extinguisher .
zz
zz
z ALWAYS know the location of the
nearest
first aid kit .
zz
zz
z
Inemergencies ALWAYS knowthe locationof thenearest
phone or
keep a phone on the job site . Also know the
phone numbers of the nearest
ambulance , doctor and
fire department . Knowingthis informationis invaluable
in the case of an emergency and could keep a serious
situationfrom becominga tragicone.
Saw Transportation Safety
■ DO NOT use the handle bars and/or front pointer as lifting
points.
■ ALWAYS userampscapableofsupportingthe weightof the
sawand theoperatorto loadand unloadthe saw.
■ If the saw must be lifted, use the lifting bale and a crane or
forkliftwitha ratedlifting capacityforthesaw. Neverattempt
tolift thesawby yourself.
■ When transporting the saw, place the saw directly inside
towingvehicletruck-bedorontotrailerandtie-downsecurely.
■ NEVER attemptto towthe untraileredsawbehind avehicle.
■ DO NOT useonslopesor onextremely unevensurfaces.
■ NEVER tipthe enginetoextreme anglesas itmaycause oil
to gravitate into the cylinder head making the engine start
difficult.
■ NEVER load, unload, or transport the saw with the blade
mounted.
WARNINGWARNING
WARNINGWARNING
WARNING
All displacement of the machine
outside the cutting area shall be
carried out with the tool not in
rotation.

PAGE 12 — FCG1 CONCRETE SAW— OPERATION & PARTS MANUAL — REV. #2 (03/10/04)
FCG1 CONCRETE SAW— OPERATION AND SAFETY DECALS
Figure 2. FCG1 Concrete Saw Decals
Machine Operation And Safety Decals
TheFCG1 ConcreteSaw isequipped withanumberofsafetydecals(Figure 2).Thesedecals areprovidedforoperatorsafetyand
maintenanceinformation. Should any ofthesedecalsbecomeunreadable,replacementscanbeobtained fromyourdealer.
P/N 36099 (ISO Blue)
P/N 25427
DECAL SHEET INTL STDS
P/N 11246
LUBRICATION
CHECK HOT BELT DRIVE
P/N 15581 P/N 15580
P/N 25491
Always use approved
respiratory protection. Adhere
to safety guidelines. OSHA
Regulations (Standards-
29 CFR) 1926.136 &1910/103
WARNING
Never operate the saw without
the guards in place. Adhere to
safety guidelines: ANSI Code
29 CFR) 1910.215.
WARNING
DEPTH
CONTROL
1
2
3
4
In
(mm)
(102)
(76)
(51)
(25)
R
O
T
A T
I
O
N
P/N: 13118
P/N 35137
To avoid injury,
you MUST read
and understand
operator’s manual
before using this
machine.
Ask for training
as needed.
This machine to
be operated by
qualified
personnel only.
P/N 35137
WARNING
MODEL
SERIAL NO.
Engine exhaust and some of
its constituents, and some dust created
of California to cause cancer, birth
defects and other reproductive harm.
by power sanding, sawing, grinding,
drillingandother construction activities
contains chemicals known to the State
Some examples of these chemicals are:
Leadfromlead-based paints.
Crystallinesilicafrom bricks.
Cementandother masonry products.
Arsenicandchromiumfromchemically
treatedlumber.
Your risk from these exposures varies,
dependingonhow often youdo this type
of work. To reduce your exposure to
these chemicals: work in aALWAYS
well ventilated area, and work with
approved safety equipment, such as
dust masks that are specially designed
to filter out microscopic particles.
CONTACT
SERVICE
DEPARTMENT
P/N 20525
P/N 25867
P/N 25485 (large)
P/N 25483
(small)
P/N 25484
(small)
P/N 25482
(large)

FCG1 CONCRETE SAW — OPERATION & PARTS MANUAL — REV. #2 (03/10/04) — PAGE 13
Intended Use
Operate the FCG1 Saw, tools and components in accordance
withthe manufacturer'sinstructions. Use ofany othertools for
statedoperationis consideredcontraryto designateduse. The
risk of such use lies entirely with the user. The manufacturer
cannotbe heldliable fordamages asa resultof misuse.
Thissawisnotintendedforwetcutting.(Theuseofwatersprayed
ontothe tool[blade] duringthe cuttingoperation).
FAMILIARIZATION
This FCG1 Saw is designed for dry sawing of concrete slabs
utilizing diamond blades. The saw has been engineered for
generalandindustrialflatsawingapplicationsthatinclude: Joint
Sawing of Green Concrete, Decorative Sawing in Cured
Concrete, Light Demolition Sawing and "V" Groove
Beveling. The simple and compact nature of the SlabSaver
makes it a perfect sawing tool for one person to operate and
transport. The saw combines innovative features, top quality
components, and a committed attention to state-of-the-art
manufacturing.
Forpeak performance,the SlabSaverhas beenengineered to
operate a powerful 4.8 Kw (6.5 HP) Honda or 5.1 Kw (7 HP)
Robin Gasoline engine and 254 mm (10") diameter diamond
blades. Thisspecial designallowsforfast,cleancutsin different
materialsat depthsfrom6.4 mmto82.6 mm(1/4"to 31/4").
For maximum performance and return on investment use:
Diamond Blades.
Retractable front & rear pointers with "tracking wheels" are
providedtosupportprecisestraightsawing. Thissystempermits
the operator to quickly adjust the blade cutting depth and
safeguardagainst "blade-creep"during sawingoperations. For
operator comfort and ease of transportation & storage, an
adjustable locking handle bar is provided.
Operator control of the saws is safely accomplished with
adjustablehandle bars,and aconvenientlyoriented raise/lower
leveranddepthadjustment wheel.Anengine-off switch(Item22
Fig. 3) located next to the handle lock allows the operator to
safelyturn theengine offfromthe operator'sposition andaway
frommovingparts.
Thejig-welded reinforcedheavy gaugesteelframe andchassis
assemblyare designedtoeliminate operationalbendingand/or
flexthat wouldleadto diminishedbladeperformance. Also, the
frame's general weight-to-strength ratio and center mounted
bladedesign ensureaccurate trackingin thecut.
A robust blade shaft bearing assembly ensures minimal flutter
and shaft harmonics providing the most advantageous
conditionsfor adiamond bladeat operatingspeeds.
Heavy-duty front and rear axles, polyurethane wheels with
permanently sealed ball bearings, and solid undercarraige
assembly provide years of reliable use. The SlabSaver
incorporatesaninnovativePosiLokraise/lowercontrolassembly
that provides fingertip control of blade orientation, infinitely
adjustablelocking bladedepth control,and depthfeed gauge.
FCG1 CONCRETE SAW— GENERAL INFORMATION
ENGINE
Pages23-27highlightfundamentalaspectsofengineinspection,
starting,and shutdown.Refertotheengine Owner'sManualfor
specific instructions regarding operation, service and
maintenance.

PAGE 14 — FCG1 CONCRETE SAW— OPERATION & PARTS MANUAL — REV. #2 (03/10/04)
CONTROLS & COMPONENTS
FCG1 CONCRETE SAW—COMPONENTS
Figure 3. FCG1 Concrete Saw
1
2
8
3
7
6
5
4
9
12
22
11
14
18
24
15
20
21
19
13
16
23
10
17

FCG1 CONCRETE SAW — OPERATION & PARTS MANUAL — REV. #2 (03/10/04) — PAGE 15
Figures3showsthelocationofthebasiccontrolsorcomponents,
forthe FCG1Concrete Saw.Listed belowisabrief explanation
ofeach controlor component
1. Hand Grips/Handlebar – Whenoperatingthesaw,place
bothhands oneach grip tomaneuverthe saw.
2. Adjustable Handle – Settocomfortableoperatingposition.
3. Rear Guide – Rearguide wheeldropsinto cut toassistin
straighttracking.
4. Air Filter – Preventsdirtanddebrisfromenteringtheengine
airintake. Keepcleaned andreplace whennecessary.
5. Recoil Starter Handle – Pull to engage and start the
engine.
6. Recoil Starter Assembly – Engages the engine when
thehandle ispulledand rewindsthestarter ropewhenthe
handle is released.
7. Wheels/Carraige Assembly – Heavy-dutypolyurethane
wheelswith permanentlysealed ballbearings.
FCG1 CONCRETE SAW—COMPONENTS
8. Diamond Blade – 19.1 mm (0.75" ) Arbor diameter. 254
mm(10")bladecapacity. Thisdiameterprovidesforadepth
ofcut from6.4mm to82.6 mm(1/4"to 31/4")depth ofcut.
9. Blade Guard – Covers saw blade and flips up to allow
bladeto bechanged.
10. BeltTension Adjuster – Adjusts belttension.
11. Front Guide – Assistsin straighttracking.
12. Front Guide Arm – Pivotsupforstorage andpivotsdown
foruse.
13. Depth Adjust Disk – Turn disk clockwise or counter-
clockwiseto adjustthe cuttingdepth upordown.
14. Fuel Tank – Use unleaded gasoline.Do not overfill.
15. Shift Knob – Moves Depth Stop Rod in or out of keyhole
slot.
16. V-Belt Cover – Removethiscoverto gainaccessto theV-
belt. NEVER operatethe sawwiththis coverremoved.
17. Arbor Shaft Grease Zerks – Conveniently located for
lubrication.
18. On/Off Switch (Engine)– Turn to the "ON" position to
allowenginetobe startedandturntothe "OFF"position to
preventaccidental starting.
19. Handle Lock – Lock handle height to a comfortable
operatingposition.
20. Screw Plunger – Lineupbottom edgeofDepth StopRod
onScrew Plungeracross fromdesireddepthlinemark.
21. Depth Stop Rod – Holdsblade aboveworking surfaceor
allowsbladetocut intoworkingsurface atspecified depth.
22. Engine Shut-off Switch – The Engine Shutdown Switch
locatednexttothehandlelockservesbothasanEmergency
Engine Shut-Off and as the primary Shutdown switch. This
allows the operator to shutdown the saw safely away from
movingparts.
23. Dust Collection – Provides forconnection tosuitable dust
collectionbag orvacuumsystem.
24. Sash – Allows for the lowering and raising of the front
guidefrom theoperator'sposition.

PAGE 16 — FCG1 CONCRETE SAW— OPERATION & PARTS MANUAL — REV. #2 (03/10/04)
Figure 4. Engine Controls and Components
INITIAL SERVICING
Theengine (Figure4) mustbe checkedfor properlubrication and
filledwithfuelpriortooperation. Refertothemanufacturersengine
manualfor instructions&detailsofoperationandservicing.
1. Fuel Filler Cap – Remove this cap to add unleaded
gasoline to the fuel tank. Make sure cap is tightened
securely.DO NOT over fill.
6. Choke Lever – Usedin thestarting ofacoldengine,or in
cold weather conditions. The choke enriches the fuel
mixture.
7. Air Cleaner – Preventsdirtand otherdebrisfrom entering
the fuel system. Remove wing-nut on top of air filter
cannisterto gainaccesstofilterelement.
Operating the engine without an air
filter, with a damaged air filter, or a
filter in need of replacement will
allowdirttoentertheengine,causing
rapid engine wear.
8. Spark Plug – Providessparkto theignition system. Clean
sparkplug oncea week.
9. Muffler – Usedto reducenoise andemissions.
FCG1 CONCRETE SAW— BASIC ENGINE
Adding fuel to the tank should be done only
when the engine is stopped and has had an
opportunityto cooldown. Inthe eventof afuel
spill, DO NOT attempt to start the engine until
thefuelresiduehasbeencompletelywipedup,
andtheareasurroundingtheengine isdry.
2. Throttle Lever – Usedtoadjust engineRPMspeed (lever
advanced forward
SLOW , lever back toward operator
FAST ).
3. Engine ON/OFF Switch – ON position permits engine
starting,OFF position stopsengineoperations.
4. Recoil Starter (pull rope) – Manual-startingmethod. Pull
thestarter gripuntil resistanceis felt,then pullbriskly and
smoothly.
5. Fuel Valve Lever – OPEN to let fuel flow, CLOSE to stop
theflow offuel.
NOTE
DANGERDANGER
DANGERDANGER
DANGER
WARNINGWARNING
WARNINGWARNING
WARNING
10. Fuel Tank – Holds unleaded gasoline. For additional
informationrefer toengineowner's manual.
Enginecomponentscangenerateextremeheat.
To prevent burns, DO NOT touch these areas
whiletheengineisrunningorimmediatelyafter
operating.NEVER operatethe enginewith the
mufflerremoved.

FCG1 CONCRETE SAW — OPERATION & PARTS MANUAL — REV. #2 (03/10/04) — PAGE 17
Figure 7. Pulley Alignment
3. Check V-belt tension by using a tension meter (13.2 Kg -
19.8Kg /6.0- 9.0lbs.)againstthe insidebelt atamid point
betweenthetwopulleys,orbydeflectingthecenterbeltata
midpoint 10mm (3/8")to13 mm(1/2"). SeeFigure8.
FCG1 CONCRETE SAW — GUARDS, COVERS AND V-BELTS
NEVER operate the saw without blade
guards and covers in place. DO NOT
operate with the front of the blade guard
raised. Thebladeexposurecannotexceed
180 degrees during operation. Adhere to
the safety guidelines of the American
National Standards Institute (ANSI)
B7.1 and B7.5.
Figure 5. Blade Guard
CHECK the following on the"blade guard" (Figure 5):
■ Ensurethecapacityofthebladeguardmatchesthediameter
ofyour diamondblade.
■ Checkthat theguard isbolted firmlyuponthe sawframe.
■ Check that the spring tensioned front cover of the guard is
firmlyseatedwiththe rearsection ofthe guard,andthereare
nogaps. NEVER lift theblade guardwhile cutting.
Figure 6.V-Belt Cover
NEVER attempt to check theV-belt with the
engine running. Severe injury can occur.
Keep fingers, hands, hair and clothing
away from all moving parts.
V-belt Alignment and Tensioning
This concrete saw is equipped with a premiumV-belt that has
been aligned and tensioned by factory personnel. The V-belt
mustbe alignedand tensionedforproper operationof thesaw.
Usethe followingprocedureto check thealignmentofV-belt:
1. Removetheboltsthatsecure theV-belt cover(Figure6)to
thesawframe.
2. Check uniform parallelism (Figure 7) of V-belt and pulley
(sheaves). Useastraight-edgeormachinist'ssquareagainst
both pulleys and adjust both pulleys until equally aligned.
V-belt Check
Aworn ordamagedV-beltcanadverselyaffectthe performance
ofthesaw.IftheV-beltisdefectiveorworn,replaceandtheV-belt
as outlined on page 18.
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION
WARNINGWARNING
WARNINGWARNING
WARNING

PAGE 18 — FCG1 CONCRETE SAW— OPERATION & PARTS MANUAL — REV. #2 (03/10/04)
FCG1 CONCRETE SAW — GUARDS, COVERS AND V-BELTS
Figure 8. V-Belt Tension Check
4. DO NOT over or undertighten theV-belt. Severedamage
can occur to the saw and engine crank shaft if the belt is
over-tensioned. Adecreaseof powertotheblade andpoor
performancewill resultifthebeltis under-tensioned(loose
onpulleys).
IftheV-beltbecomewornordamaged,replaceitwith P/N15082
(Gates/Optibelt3VX335).
3. Tightentheadjusting hexscrew(4) whileholding theengine
inplace tomaintain pulleyalignment.(a screwdrivercan be
usedas alever atthe rearbeltguard mountingboss tohold
thebackof theengine whileadjustingV-belt tension.)
4. Re-tightenthe lockingnut(3).
5. With V-belt held in proper alignment, (engine parallel with
the frame), re-tighten the 4 engine mounting hex screws.
Verify thatallhexscrewsare properlytightened.
To Tighten the V-belt:
NOTE V-belt alignment must be rechecked after adjusting belt
tension.
To Remove and Replace the V-belt:
1. Remove the 3 hex screws holding the V-belt guard and
removethe guard.
2. Loosenthe4enginemountinghex screws.(item 2,Figure9)
3. Loosen locking nut on the V-belt tension adjuster (item 3,
Figure 9). Loosen the tension on the V-belt by turning the
tensionadjuster hexscrew (item 4,Figure 9).
4. Pull the engine ahead to provide slack in theV-belt.
5. Loosenthe 4arborshaft hexscrews, (item1, Figure9).
Figure 9. V-Belt Tension Adjust
1. WithV-belt guard removed, loosen the 4 engine mounting
hexscrews. (items2Figure 9)
2. LoosenlockingnutontheV-belt tensionadjuster,(3 ).
6. Remove the two outer arbor shaft hex screws allowing the
outsideoftheshafttodrop,(BinFigure10),allowingremoval
oftheV-belt.
7. ReinstallnewV-belt.
8. Re-installand tightenarborshaft hexhead screws.
9. WithV-beltheld inproperalignment, re-tightenthe 4engine
mountinghexscrews.(FollowV-belttightening procedures.)
10.Re-install beltguard with3 hexscrews.
Figure 10.V-Belt Removal

FCG1 CONCRETE SAW — OPERATION & PARTS MANUAL — REV. #2 (03/10/04) — PAGE 19
Failure to thoroughly inspect the
diamond blade (Figure 11) for
operational safety could result in
damage to the blade, the saw, and may
cause injury to the user or others in the
operating area. All damaged blades
must be discarded.
Figure 11. Diamond Blade
1. Drive Pin Hole – Acommonlylocatedholeonthe diamond
blade core that prevents operational blade slippage
betweenthe inner&outer bladeflanges (collars). Inspect
the diameter of the hole to ensure there is no distortion,
and that a snug fit develops between the hole and drive
pin.
2. Stress Relief Holes (Gullets) – Check the steel core for
cracks that may have propagated from the slots and/or
gullets.Cracks indicate extremefatigue failure andif sawing
continues, catastrophic failure will occur.
3. Edge Of The Steel Core – Check the diameter edge for
discoloration (blue oxidation) indicating an overheating
condition caused by insufficient cooling water/air.
Overheating of blades may lead to loss of core tension
and/or increase the possibility for blade failure. Check to
make sure the steel core’s width is uniform about the rim of
the blade, and not succumbing to an “under cutting”
condition brought about by highly abrasive material or
improper under cutting core protection.
4. Directional Arrow – Check to ensure that the blade is
oriented properly on the blade shaft for sawing. Reference
thedirectionalarrow in theblade and placeit so thedirection
of rotation “downcuts” with the turn of the shaft.
5. Diamond Segment or Rim – Ensure there are no cracks,
dings, or missing portions of the diamond segment/rim. DO
NOT
use a blade that is missing a segment or a portion
of
the rim . Damaged and/or missing segments/rims may
cause damage to your saw, and injury to the user or others
in the operating area.
6. Specifications – Ensure that theblade specifications, size,
and diameter properly match up to the sawing operation.
Utilizing a diamond blade not matched properly to the task
may result in poor performance and/or blade damage.
7. Arbor Hole – It is essential that the arbor hole diameter
properly matches the blade, and that it is free from
distortions. Correct blade flanges (collars) must be used.
Theinsideface of theflanges mustbe clean &free ofdebris.
An out of round arbor condition will cause damage to the
blade and the saw.
8. MAX RPM – This RPM reference is the maximum safe
operating speed for the blade selected. DO NOT use
blades rated at a lower rotational speed than the rated
RPM of the saw (6000 RPM). Exceeding the MAX RPM is
dangerous, and may cause poor performance and may
damage the blade. All blades must be designed to meet or
exceed the maximum spindle RPM.
SPECIFIC TOOLS TO BE USED
Thissawis touse tools(blades) asfollows:
SteelCore Segmentedor ContinuousDiamond Rim
CuttingWheel.
Anyother typeof toolisnot tobe used. SeeTable 4forspecific
bladeusage formaterial.
WARNINGWARNING
WARNINGWARNING
WARNING
FCG1 CONCRETE SAW — BLADES
Adhereto theBlade Manufacturer's
recommendations on handling,
storage,and safeusage ofblades.
NOTE

PAGE 20 — FCG1 CONCRETE SAW— OPERATION & PARTS MANUAL — REV. #2 (03/10/04)
1. Blade Guard -Pivot thebladeguardfrontcover alltheway
back. The guard tension spring will keep the front cover in
position.
2. Blade Hex Nut - Unscrew the blade shaft nut (right side
loosensclockwiseandtightenscounter-clockwisewhilethe
leftsideloosenscounter-clockwise andtightensclockwise.
DO NOT overtightenthe nut(approximately45-50 ft.lb/61-
68N/m) whenfinalizing theassembly.
3. Outside Blade Flange (Collar) - Ensure that the outside
blade flange is placed flush against the diamond blade.
Theinside surfaceof theflange mustbe freeof debrisand
permita tightclosure onthe surfaceofthe bladecore.
Cutting Depth
The FCG1 Concrete Saw has a capacity for a 254 mm (10")
blade with an 19.1 mm (0.75") Arbor diameter. This allows a
cuttingrange from 0-82.6 mm(0"to 31/4").
FCG1 CONCRETE SAW — BLADE PLACEMENT
Failure to thoroughly inspect the diamond
blade for operational safety could result in
damage to the blades or the saw and may
cause injury to the user or others in the
operatingarea.
BLADE PLACEMENT
Diamond Blades
Selecting the diamond blade TYPE and GRADE defines how
the blade will perform both in cutting speed and blade life.
Selection of the proper diamond blade consists of:
z Material tobe Cut
z Type of Saw Being Used
z Spindle Speed of Saw
z Hardness Characteristicsofthe Material
z Performance Expectations
Factors for sawing economy:
z Type of Blade
z Depthof Cut
z SawingSpeed
z Characteristicsof theMaterialBeing Cut
Blade Speed
Adiamondblade’sperformanceisdirectlyconnectedtospecific
peripheral(rim)speeds.
The following shaft rotational speeds have been factory set to
ensureoptimumbladeperformance.
z FCG1- 254 mm(10”)Capacity -6000 RPM.
Operating saw blades at rotational
speeds greater than those specified by
themanufacturer can causeblade dam-
age, and may injure the user or others in
theoperating area.
WARNINGWARNING
WARNINGWARNING
WARNING
D
WARNINGWARNING
WARNINGWARNING
WARNING
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