SAINT-GOBAIN Clipper CK31 User manual

CK31
OPERATING INSTRUCTIONS

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The undersigned manufacturer:
SAINT - GOBAIN ABRASIVES S.A.
190, BD J.F. KENNEDY
L- 4930 BASCHARAGE
Declares that this product:
Floor saw: CK 31 D KSA Code: 70184621027
is in conformity with the following Directives:
European Machinery Directive 2006/42/EC
Electromagnetic Compatibility Directive 2004/108/EC
and European standard:
EN 13862 –Floor cutting-off machines –Safety
Declaration of conformity

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CK31
OPERATING INSTRUCTIONS
1Basic Safety Instructions 6
1.1 Symbols 6
1.2 Machine plate 8
1.3 Safety instructions for particular operating phases 8
2General description of the CK31 9
2.1 Short description 9
2.2 Layout 9
2.3 Technical data 11
2.4 Vibration emission declaration 12
3Assembly and commissioning 13
3.1 Tool assembly 13
3.2 Left or right cut 13
3.3 Water cooling system 13
3.4 Starting the machine 14
4Transport and Storing 15
4.1 Securing for transport 15
4.2 Transport procedure 15
4.3 Long period of inactivity 15
5Operating the CK31 16
5.1 Site of work 16
5.2 Cutting method 16
6Maintenance and service 18
6.1 Maintenance of the machine 18
6.2 Maintenance of the engine 20
7Faults: causes and cures 25
7.1 Fault-finding procedures 25
7.2 Trouble-shooting guide 25
7.3 Customer service 26

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1 Basic Safety Instructions
The CK31 is exclusively designed for the cutting of floors made of asphalt, green and cured
concrete (reinforced or not) as well as of industrial cement.
Uses other than the manufacturer's instructions shall be considered as contravening the regulations.
The manufacturer shall not be held responsible for any resulting damage. Any risk shall be borne
entirely by the user. Observing the operating instructions and compliance with inspection and
servicing requirements shall also be considered as included under use in accordance with the
regulations.
1.1 Symbols
Important warnings and pieces of advice are indicated on the machine using symbols. The following
symbols are used on the machine:
Read operator’s instructions
Ear protection shall be worn
Rotation direction of the blade
Never move the machine with the blade
running idle.
Set the handle in this position to move the
machine forwards
Set the handle in this position to move the
machine backwards
Set the handle in this position to disengage
the clutch
Set the handle in this position to engage
the clutch

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Press the button in this direction to raise the
blade
Press the button in this direction to lower
the blade
Parking brake on
Parking brake off
Emergency Stop
Danger: risk of cut

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1.2 Machine plate
Important data can be found on the following plate located on the machine:
1.3 Safety instructions for particular operating phases
Before commencing work
Before commencing work, make yourself familiar with the working environment at the place of
use. The working environment includes: obstacles in the area of work and manoeuvre, the
firmness of the floor, necessary protection at the site relating to public thoroughfares and the
availability of help in the event of accidents.
Check for correct mounting of the blade regularly.
Immediately remove damaged or badly worn blades, as they endanger the operator whilst
rotating.
Always cut with the blade guard in position.
Only fit NORTON diamond blades to the machine! The use of other tools can damage the
machine!
Attention is drawn to the use of BS2092 safety goggles in conformity with specified Processes
No.8 of the Protection of Eyes Regulation 1974, Regulation 2(2) Part 1.
For security reasons, never leave the machine unattended, untied or unlocked.
While the engine is running
Do not move the machine whilst the blade is running idle.
Do not run the machine without the security guards in place.
Apply cooling water continuously whilst cutting and in good time!
Diesel powered machines:
Always use the fuel advised.
In confined areas, exhaust gases should be evacuated and the job site properly aerated.
Diesel machines, which by their nature emit toxic exhaust gases, must not be used in places
prohibited by the Health at Work Act 1974 or which are prohibited by Factory Inspectors or
Safety Officers.
Diesel is flammable. Before filling the tank, shut down the engine, extinguish all open flames and
do not smoke. Take care that no diesel is spilled on any motor part. Always wipe up spilled fuel.
Machine type
Serial number
Power
Safety standard
Blade speed
Machine Model
Machine Code
Bore diameter
Max. blade diameter
Year of production
Weight

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2 General description of the CK31
Any modification, which could lead to a change in the original characteristics of the machine, may
be done only by Saint-Gobain Abrasives S.A. who shall confirm that the machine is still in
conformity with the safety regulations. Saint-Gobain Abrasives S.A. keeps the right of making
technical or design modification without prior notification.
2.1 Short description
The Floor Saw CK31 you have chosen is used for repair works in concrete and asphalt on
highways and runways, for trench sawing or cable loop cutting applications. It can be used for either
wet or dry cutting operations. It can be easily transported.
All component parts on the CK31 are assembled to a high quality standard, ensuring long life,
reliability and a minimum of maintenance.
Special types of blades are available for asphalt, green concrete, cured concrete (reinforced or not)
as well as for industrial cement flooring.
2.2 Layout
Made of jig welded open profile steel, the CK31 is stable but at the same time, easily transportable.
The operator’s handles (1) can be adjusted to a comfortable position, or removed for transportation.
The main operating and safety components are in reach near the operator on the machine panel
(2).
The engine frame (3) comprises the engine, the feed movement devices, and the hydraulic pump.
The front and back pointers (4) allow the operator to make precise cuts easily.
The blade guard (5) fully protects the operator and his working environment. It is firmly fixed to the
main frame. A small locking handle (25) can be opened to remove the guard to change blades. It
can be opened on the front to cut up to a wall.

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The water cooling system (6) is composed of a water tank tap (9) and two water nozzles on the
blade guard ensuring adequate flow of water to both sides of the blade. External water supply has to
be used by connecting to the palm coupling.
The machine can be lifted using the lifting eyes (7). The pivoting frame, hinged on the rear axle, is
supporting the engine, the blade shaft assembly, and the protecting guards. 8 heavy-duty belts drive
the blade.
The DEUTZ Motor F2L 2011 (8) with 31HP is started with a key. The following picture is showing
the main control panel with its components:
Two lights are showing the oil pressure (11) and the load of the battery (13). The emergency stop
(12) is easy to reach for the operator. You can easily read the temperature of the engine (10) and
the working time on the hour meter (15).
You can precisely set the depth of cut using the gauge (16), and make many cuts at the same depth
using the maximum depth locking system (14). The blade is raised and lowered using the toggle
switch (19). The speed of raise and lower is regulated using the control (18).
The machine is started using a key (21). The rotational speed of the engine is set with the handle
(17), and can be checked with the tachometer (24). To move the machine, you have to take it off the
parking position (22). You must then engage the clutch (23) and set the speed forward or backward
with the handle (20).

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2.3 Technical data
Engine
Deutz F2L 2011 (22,8kW/ 31HP)
Fuel
Diesel complying with the following minimum specifications :
DIN EN590 or BS 2869 or ASTM D 975 –1D / 2D or NATO
Code F-54/f-34/f-44 or XF63
Oil (Motor)
Oil complying with the following minimum specifications:
API CG4-CH-4 or ACEA E3-96+E4-98 or Deutz DQC II
Viscosity recommended : SAE 10W-30 (outside temperature
between -20ºC and 30ºC)
Oil (Reversing gear box)
Fully synthetic oil with a viscosity of SAE 90
Oil (Hydrostatic feed movement)
Hydraulic oil with a viscosity equivalent to the one of an
automotive oil 20W-50
Oil (Hydraulic system)
Under 0°C : VG32 (As per ISO VG DIN51519)
HLP32 (As per DIN51519)
Cinematic viscosity at 40°C 22,8-35,2mm2/s
(cSI)
0-30°C : VG46 (As per ISO VG DIN51519)
HLP48(As per DIN51519)
Cinematic viscosity at 40°C 41,4-50,6mm2/s
(cSI)
Over 30°C : VG68 (As per ISO VG DIN51519)
HLP68(As per DIN51519)
Cinematic viscosity at 40°C 61,2-74,8mm2/s
(cSI)
Fuel tank
30 L
Starter
Electric start with key
Blade raise system
Electro-hydraulic
Max. blade diameter
700 mm
Bore
25,4 mm
Max. cutting depth mm
280 mm
Flange diameter
150 mm
Blade shaft speed
1550 min-1
Driving belts
8
Machine dimensions
(length x width x height)
1430x820x1280mm
Weight
660 kg
Max. operating weight
710 kg
Sound pressure level
100 dB (A) following ISO EN 11201
Sound energy level
114 dB (A) following ISO EN 3744

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2.4 Vibration emission declaration
Declared vibration emission value in accordance with EN 12096
Machine
Model / code
Measured vibration
emission value a m/s2
Uncertainty K
m/s2
Tool used
Model / code
CK31 KSA
70184621027
9.4
0.8
CC Pro Ø700x25.4mm
70184624857
Values determined according to procedure described in annex F of EN 13862
Measurements are made with new machines. Real values in the field could vary the simple
one with the double according to operating conditions, depending on:
oMaterial
oCutting depth
oMachine wear
oLack of maintenance
oTool not adapted to application
oTool in bad shape
oNon-specialised operator
Vibrations exposure time depends on cutting performance too
(adaptation machine / tool / material / operator)
When evaluating risks due to hand-arm vibration, you need to take into account effective
usage at rated power of machine during a full day of work; quite often you will realise that
effective utilisation time represents around 50% of overall duration of work. You have to
consider, of course, breaks, water feeding, preparation of work, time to move the machine,
disk mounting…

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3 Assembly and commissioning
Before beginning the work with the CK31, you have to assemble some parts.
3.1 Tool assembly
Only use NORTON blades with the CK31.
A blade with a maximum diameter of 700 mm can be fitted. All tools used must be selected with
regard to their maximum permitted cutting speed for the machine’s maximum permitted rotation
speed.
Before mounting a new blade, switch the machine off.
To assemble a new blade, follow these steps:
Take the water nozzle off the blade guard.
Release the locking handle (25).
Take the blade guard (5) off the machine.
Untighten the hexagonal screw on the blade shaft with the 19mm wrench. (CAUTION: on the
right hand side of the machine, the screw is left-threaded, and the left hand side of the machine,
the screw is right-threaded.)
Remove the outer flange.
Clean the flanges and blade shaft and inspect for wear.
Mount the blade on the shaft ensuring that direction of rotation is correct. Wrong direction of
rotation blunts the blade quickly.
Replace outer blade flange.
Tighten screw with 19mm wrench.
Reassemble the blade guard and make sure it is securely tighten with the handle (25).
Reconnect water nozzle.
The blade bore must correspond exactly to the blade shaft. Cracked or damaged bore is dangerous
for the operator and for the machine.
3.2 Left or right cut
Take the water nozzle off the blade guard.
Release the locking handle (25).
Take the blade guard (5) off the machine.
Disassemble the flange cover from the other side of the machine, and reassemble on the side
you used to have the blade guard.
Assemble the blade as described in 3.1. on the side where you used to have your flange cover.
Reassemble the blade guard making sure that the handle (25) is securely locked.
3.3 Water cooling system
Open water-tap (note that handle on water-tap should be in line with water-flow).
Ensure that water is flowing freely in the circuit and delivered adequately to both sides of the blade,
as insufficient water supply may result in premature failure of the diamond blade.
In case of frost, empty the water cooling system.

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3.4 Starting the machine
Make sure the blade is raised clear up the ground before starting the machine, and that the clutch is
disengaged. Put the throttle lever (17) on the middle position.
Insert the key (21)
You don’t have any operating voltage in position 0.
Turn the key clockwise. In position 1, you have operating
voltage. Therefore, the oil pressure light (11) and the
battery load light should be on.
Push the key in and turn further clockwise against the
spring pressure. The engine starts in position 3. Release
the key as soon as the engine starts. The oil pressure
light and the battery load light should go out.
Do not actuate the starter for more than 20 seconds. If
the engine does not catch, wait a minute then try again.
If the motor does not catch after 2 attempts, please refer
to the Fault table (see 7.2) to check the problem.
The engine temperature meter (10) should remain in the green sector most of the time. It should
rarely enter the yellow-green sector. If pointer enters the orange sector, engine is overheating. Turn
off the machine, and establish cause from Fault table (see 7.2.).

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4 Transport and Storing
Take the following measures in order to transport and store the CK31 securely.
4.1 Securing for transport
Before transporting the machine:
Remove the blade.
Empty the water system and disconnect the machine from the water supply.
Raise the guide-a-cut in its upright position.
Raise the cutting frame to its highest position.
Take the key off the starter.
4.2 Transport procedure
The machine can be moved on a flat surface using its wheels.
a) Driving the machine
Make sure the clutch is disengaged (23), the parking brake is tightened (22) and the speed
handle is in middle position.
Start the engine. Then engage the clutch and use the speed handle to move the machine
backwards or forwards, and to regulate the speed.
b) Pushing the machine
Disengage the clutch of the machine (23) and the parking brake (22) and push it on the handle (1)
without starting the motor.
c) Lifting using a crane
Make sure that crane can lift the weight of the machine. Use the metal lifting eye (7), located above
the engine when lifting the CK31 with a crane. This lifting eye must not be used to lift the saw if the
blade is stuck in the cut.
CAUTION: Nobody is allowed to go under the machine while it is lifted by the crane.
4.3 Long period of inactivity
If the machine is not going to be used for a long period, please take the following measures:
Completely clean the machine.
Loosen the drive belts.
Change the motor oil.
Disconnect one of the terminal of the battery so that the battery does not run empty
Empty the water system.
The storage site must be clean, dry and at a constant temperature.

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5 Operating the CK31
5.1 Site of work
Before you start working, please check the following points:
Remove from the site anything, which might hinder the working procedure.
Make sure the site is sufficiently well lit.
Make sure you have a continual adequate view of the working area so you can intervene in the
working process at any time.
Keep other staff out of the area, so you can work securely.
5.2 Cutting method
In this section, you can find instructions to make a straight cut at the desired depth.
5.2.1 Preparing your cut
Before starting the machine,
Draw a line on the floor over the cutting length.
Make sure you have filled the engine tank with fuel, and the water tank with water, or that you
have connected the blade guard to the water supply. No diesel is supplied with the machine.
The engine is shipped with oil. Check oil level before starting. Top up if required (see 6.2.).
Make sure you have assembled the correct blade as recommended by the manufacturer
depending on the material to be worked, the working procedure (dry or wet cut) to be carried
out, and the efficiency required.
Make sure that the flanges securely hold the diamond blade.
Make sure that the blade is not touching the floor before starting the engine.
Roll the machine until the blade is over the line.
Lower the guide-a-cut so it touches the line. The back guide should also be on this line.
Set the speed handle in the middle position, so that if you engage the clutch, the machine will
not move unexpectedly. Make also sure that the clutch is disengaged and the parking brake is
tightened.

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5.2.2 Cutting the floor
You can now start the engine.
To make your cut,
Lower the pivoting frame until the blade slightly touches the floor. Then set the depth gauge to 0.
Open water valve to control the amount of water required for the type of blade, using 15 to
25l/min for wet and 1-2l/min for dry cutting, dust control. Check for minimum water level
regularly.
Set the rotation of the blade with the throttle lever (17). You can check the speed on the meter
(24).
Lower blade into the cut. Once the required depth of cut is reached, you can release the parking
brake, engage the clutch and use the back and forward handle to regulate speed. Always cut
with the machine moving forward, as cutting backwards will damage the blade and the blade
shaft. Follow the line with the pointer. The feed speed must be adjusted depending on the
material being cut, and depth of cut.
At the end of the cut, raise the blade out of the cut, switch off the engine and shut-off the water.
5.2.3 Locking of the cutting depth
If you have to make several cuts at the same depth, you can lock the maximum depth your machine
will lower to. When you reach the depth for the first time, tighten the locking screw (14) until you
reach the stop.
5.2.4 Setting of the direction
Because of the rotation of the blade, the floor saw cannot cut straight in normal operation.
Therefore, you have to adjust the direction using the screw (30 below):
If you turn the screw clockwise, the floor will turn right
If you turn the screw anti-clockwise, the floor will turn left

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6 Maintenance and service
ATTENTION : to perform maintenance on the machine, always switch it off. Always wear a dust
protection mask and safety goggles while performing the maintenance of the machine.
6.1 Maintenance of the machine
To ensure a long-term quality from the cutting with the CK31, please follow the maintenance plan
below:
Regular service period
Perform at every
indicated period
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After one hour of work
Begin of the day
During the changing of the tool
End of the day
Every week
Every month
After a fault
Every year
Whole machine
Visual control (general
aspect, watertightness)
Clean
Oil (hydrostatic)
Control and refill
Flange and blade fixing devices
Clean
Belts tension
Control
Water hoses and nozzles
Clean
Hydraulic hose and connectors
Control tightness
Engine housing
Clean
Reachable nuts and screws
Tighten up
Reversing gear box
Change oil
Hydrostatic feed movement
Change oil
Grease nipple (pos.34 and 36)
Grease
Grease nipple (pos. 35)
Grease
Adjustment and replacement of the belts
After one hour of work, the belts heat and stretch.
Therefore, you have to re-tension them.
To check the belts, remove the cap 31, and press with
normal pressure on the belts. The displacement should
be approx. from a belt thickness.
To adjust the belts’ tension, loosen the nut (32) with the
36mm spanner. Then tighten the belts by turning the
screw (33) (clockwise: increases belt tension). Then re-
tighten the nut (32).
To change the belts, firstly remove the belt guard by
untightening the 3 screws. Loose the nut (32) and turn the
screw (33) until the belts are loose. Then put new belts on
the pulleys and make sure the pulleys are well aligned.
Re-assemble the belt guard and re-tension the belts with
the screw (33). Then re-tighten the nut (32).
Always use a matched set of belts. Do not replace single belts. After controlling or retightening
the belts, reassemble the belt guard on the frame of the machine.

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Grease
You must grease the nipples 34, 35 and 36 on both side
of the machine regularly with Energrease LS2 BP.
Oil change for the hydraulic raise/lower system
The hydraulic unit (37) is first filled with hydraulic oil “BP-
Batran HV-68”. The old oil can be removed from the unit
through the filling hole. To remove the old oil,
disassemble the unit and turn it over.
Oil change for the reversing gear box
Disassemble the gear box (38). Change the oil (SAE 90,
fully synthetic, 0,35 litre) using the drain screw on the left
side of the gear box. Then reassemble the gear box.
Make sure than the belts are correctly tightened.
Oil change for the hydrostatic of the feed movement
Let the oil drain through the drain screw (40). Re-tighten
then this screw. Disassemble the balancing tank (39) and
empty it from its remaining oil. Reassemble the balancing
tank and fill it with 4,6 litres engine oil 20W50.
CAUTION: Please dispose of used oil in a manner that is compatible with the environment. We
suggest you to take used oil in a sealed container to your local recycling centre or service station for
reclamation. Do not throw it in the trash, pour it on the ground or down in a drain.
Cleaning of the machine
Your machine will last longer if you clean it thoroughly after each day of work.

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6.2 Maintenance of the engine
Regular service period
Perform operating hour interval

Each use
First month or 25 hours
Every 250 hours
Every 500 hours
Every 1000 hours
Engine oil
Check level (5)
Change (4)
Oil filter
Change (2)
Fuel filter
Change (3)
Cooling air zone
Check-Clean
Air cleaner filter
Clean (dry cut)
Clean (wet cut)
Change the cartridge
Valve clearance (1)
Check and adjust (only to be
done by a DEUTZ-specialist)
Fuel filter
Replace
Belt for alternator
Check
Service place on the engine