OWNERS MANUAL - Unicon Concrete
Contents
1. W LL Part No 241112 241113 241114 241115 241116 241117 241118 241119 241120 241121 241122 241123 241124 241125 241126 241127 241128 235104 241129 241124 241125 241126 Frame Assembly GC55 Only DESCRIPTION FRAME GC55 REAR POINTER GC55 GC25E SCR 8 X 65 1 25 DIN931 HEX HEAD CAP WASHER M8 DIN125 FLAT WASHER M4 DIN125 FLAT NUT M8 1 25 LOCK DIN985 NUT 0 7 LOCK DIN985 GROMMENT GC55 WHEEL W BEARING GC55 GC25E WASHER M8 X 24MM OD DIN9021B WASHER LOCK M8 DIN127 SCR M8 X 20 1 25 DIN933 HEX HEAD CAP SCR 4 X 12 0 7 DIN933 HEX HEAD CAP SCR M8 X 65 1 25 DIN931 HEX HEAD CAP FRONT AXLE GC55 GC25E SCR M8 X 35 1 25 SOCKET HEAD CAP DIN912 BRUSH WHEEL OPERATOR S RIGHT GC55 GC25E BRUSH WHEEL OPERATOR S LEFT GC55 GC25E SQUEEGEE ASSEMBLY ONLY GC55 GC25E 30 Qty Oo AN O 00 Part No 241038 241039 241040 232110 235104 241041 241042 241043 241044 241045 300245 235013 235103 241040 241046 241047 241048 241049 241050 Frame Assembly GC25E Only DESCRIPTION FRAME GC25E SCR 8 X 65 1 25 DIN931 HEX HEAD CAP REAR POINTER GC55 WASHER M8 DIN125 FLAT WASHER M4 DIN125 FLAT NUT M8 1 25 LOCK DIN985 NUT 0 7 LOCK DIN985 GROMMET GC55 WHEEL W BEARING GC55 WASHER M8 X 24MM OD DIN9021B WASHER LOCK M8 DIN127 SCR M8 X 20 1 25 DIN933 HEX HEAD CAP SCR 4 X 12 0 7 DIN933 H2. DEPTH CONTROL ASSEMBLY GC55 VVASHER M6 DIN 125 FLAT VVRENCH UNIVERSAL KEY 5 X 5 X 45mm CONDUIT 14 5mm D x 10mm ID FLEXIBLE CUTTING HEAD FLANGE GC25E CABLE POWER W FM TWIST LOCK GC25E KEY 3 16X3 4 NUT 8 1 25 LOCK DIN985 38 Qty EL o o Part No 241079 241080 241081 241082 241083 241084 27539 233041 241108 241109 241110 241111 9201074 241041 NOTES 39 Saint Gobain Abrasives 2770 West Washington Stephenville TX 76401 Phone 800 554 8003 Fax 800 443 1092 WARNING Some dust created by power sanding sawing grinding drilling and other construction activities contains chemicals known to cause cancer birth defects or other reproductive harm Some examples of these chemicals are e Lead from lead based paints e Crystalline silica from bricks and cement and other masonry products and e Arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals work in a well ventilated area and work with approved safety equipment such as those dust masks that are specially designed to filter out microscopic particles
3. DIN933 SCR M6 X 16 1 0 DIN933 WASHER M12 DIN125 FLAT WASHER M8 DIN125 FLAT WASHER M6 DIN125 FLAT NUT LOCK M12 1 75 DIN985 WASHER LOCK M8 DIN127 WASHER LOCK M6 DIN127B NUT M12 1 75 DIN934 HEX NUT M6 1 0 DIN934 HEX SCR M6 X 16 1 0 DIN912 SHCS BRACKET DEPTH CONTROL MOUNT GC55 BRACKET DEPTH CONTROL MOUNT GC25E BUSHING BLADE GUARD GC55 GC25E 25 Qty 1 N c M2 HAH MD AH A gt a Part No 241005 241006 241007 241008 241009 241010 300323 241011 241012 235048 27505 232110 27539 27017 300245 300279 27007 300833 232113 241013 241100 241014 Item ar WP Blade Shaft Assembly GC55 and GC25E DESCRIPTION CUTTING HEAD ASSEMBLY GC55 GG25E BLADE SHAFT GC55 GC25E BEARING COVER BLADE SHAFT GC55 GC25E BEARING RADIAL 6204 RS RETAINING RING E STYLE 19mm X 1 8mm DIN6799 26 Part No 241015 241016 241017 212142 241018 Item DOR co TO 10 11 12 13 14 15 16 17 18 Depth Control Assembly GC55 and GC25E DESCRIPTION DEPTH TUBE GC55 GC25E FIT GREASE ZERK M6 X 1 0 SCR DEPTH CONTROL GC55 GC25E DEPTH CONTROL MOUNT GC55 GC25E SPACER HAND WHEEL GC55 GC25E HAND WHEEL GC55 GC25E KEY 3 16X3 4 CLAMP HOSE 13 16 TO 1 3 4 X 1 2 W WORM TYPE DEPTH GAUGE POINTER GC55 GC25E BELLOWS GC55 GC25E SCR M5 X 10 0 8 DIN916 SET CUP POINT RETAINING RING C STYLE 10mm X 1 0mm DIN471 RNOB VV THREADED STUD M6 X 15 1 0 VVASHER M4 X 19mm X 2m
4. and to create an area where a controlled crack will occur With the joint in place the concrete will normally crack in a straight line underneath the joint The idea behind cutting the green concrete is that the sooner the stress relieving joints are made the better control over the random cracking will be obtained For most green cutting the depth of cut is made at 2596 of the overall thickness of the concrete for example if the concrete is 6 thick the cutting depth would be set to 1 1 2 deep One important fact to remember is that Green Concrete is any concrete that has set up but not hardened For concrete to become fully hardened it may take 5 to 7 days There are a few factors that affect green concrete cutting quality and time that the cutting can begin The following list is extremely important to follow and to understand in order to create a good quality cut with no spalling or chipping of the cut line 1 The concrete must set up long enough to hold the aggregate in place If not the aggregate will tumble and move when the Diamond Blade contacts it causing internal damage to the concrete and possible tearing or spalling of the concrete surface The aggregate along with the concrete must be cut for proper crack control With out proper set up the aggregate will roll or move within the concrete creating voids and spalling or chipping of the cut line will occur Concrete set up is the MOST important issue to obtaining a quality cut line wh
5. concrete temperature Cooler the concrete the longer the set up time 17 5 6 Check blade specification The improper blade specification will create additional spalling or chipping of the concrete For best results use a Norton GMAX series Blade The Norton GMAX series have unique features to improve the green concrete cut quality and the overall efficiency of the blade while cutting green concrete The GMAX blade provided with the GC55 was designed exclusively for use on this product to provide maximum performance and a precision cut appearance Check blade for wear As the blade loses width the cut appearance will get worse Blades with segments that look like a knife blade need to be replaced immediately as a blade in this condition will create a poor quality cut line Check concrete surface for flatness Replace the blade with a new blade of the same specification Replace blade with the correct specification Cut Appearance Previously Fine But Now Constantly Spalling or Chipping On One Side Of The Cut 1 2 3 Check for vvarped blade vvarped or out of tension blade will create a cut that has spalling and chipping Replace blade if necessary Check the tracking on saw Check that the machine is being pushed in a straight line Thin Shell Chipping of Concrete 1 Wait 1 to 2 hours for the concrete cure depth to increase Shell chipping is caused when the top layer of concrete is curing at a faster r
6. diamond for fast green concrete cutting The improper bond will not cut green concrete properly When to Start Green Concrete Cutting Timing is the most important aspect of cutting green concrete The time that the operator can start cutting will vary depending on the key factors listed above For example if the concrete has a high water to cement ratio or the day is cooler then more time is required for the concrete to properly set up and hold the aggregate in place Typically we are finding that starting around 5 to 6 hours after finishing good results can be obtain We find in our testing that at 16 hours in gives the best results These times to start are assuming that the concrete has set up long enough to hold the aggregate in place Green Concrete Cutting Trouble Shooting Spalling or Chipping On Both Sides of Cut 1 Wait at least 1 to 2 more hours before cutting The very good cut appearance is achieved at 5 to 6 hours after finishing complete The best cut appearance occurs when the concrete has set up enough for the aggregate to be held in place which may take up to 16 hours The actual time to begin cutting will depend on many factors such as concrete mixture PSI concrete type sand type and amount and other materials water to cement ratio more water the longer the set up aggregate size and type concrete additives some speed up while others slow down the set up time environmental factors Sun wind rain temperature
7. fuel tank while the engine is hot or running Do not start the engine near spilled fuel Never use the fuel as a cleaning agent Engine components can get extremely hot from operation To prevent burns do not touch the engine or related parts while the f engine is running or immediately after it is turned off Never operate the engine vvith any heat shields guards removed Reep all guards in place vvhen operating any piece of equipment Reep hands feet hair and clothing avvay from all rotating parts Lethal Exhaust Gas use only in vvell ventilated areas Engine exhaust gases contain poisonous carbon monoxide which is 2 orderless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Never tamper with the governor components of settings to increase the maximum speed Severe personal injury and damage to the engine or equipment can result if operated at speed above maximum Always obey the maximum speed rating of blade A DO NOT LIFT THE SAW BY THE HANDLE BARS A VVARNING Dust and Silica Warning Grinding cutting drilling of masonry concrete metal and other materials can generate dust mists and fumes containing chemicals known to cause serious or fatal injury or illness such as respiratory disease cancer birth defects or other reproductive harm If you are unfamiliar with the risks associated with the particular proces
8. into the cut If the engine starts to die slow down the rate of feed If the machine tries to climb out of the cut slow down the rate of feed 8 When the end of the cut is reached slowly raise the blade out of the cut by rotating the Hand Wheel counter clockwise until the blade is at least one 1 inch above the ground 9 Only move the saw in reverse with the blade in the raised position 14 10 moving the savv to a nevv location be sure the blade is not touching the ground Alvvays pay close attention to vvhere you are moving and where the blade is at all times D Cutting Technique Lower the blade into the concrete to the required depth by turning the hand wheel clockwise Push the saw steadily forward using the front pointer as a guide Exert enough forward pressure so that the engine begins to labor but does not slow down If the saw begins to stall reduce the forward movement until full rpm is restored to the blade If the saw stalls raise the blade out of the cut before restarting Avoid excessive side pressure or twisting of the blade in the cut When cutting for best performance do not cut at more than 1 1 2 deep per pass Making multiple shallow passes will increase blade life speed of cut and decrease engine motor loads Additional Guide Lines For Sawing e Understand and follow all of the instructions in this owner s manual e n critically hard aggregate be careful not to feed too quickly as it m
9. 1 The collar used to support the turn handle s screw should be checked after each use to make sure it is lubricated and turning freely If more lubricant must be added NLGI 2 aluminum complex type grease is recommended E Dust Removal System Adjustment The GC55 and GC2E are equipped with a fully adjustable non scratching Dust removal system which helps stabilize the machine by pushing debris way from wheels and undercarriage of the machine Depending on the surface and wear the Dust Removal System may need adjustments from time to time The Dust removal system consist of two Brushes located in front of the Front Wheels and a large Squeegee Assembly located under the machine and in front of the rear wheels When this system is properly adjusted the front wheel Brushes and the Rear Wheel Squeegee System will barely touch the work surface Before making any adjustments turn off the machine and disconnect the spark plug 5 To adjust the Rear Wheel Squeegee Assembly 1 Loose the Squeegee Assembly mounting hardware items 1 amp 3 2 Position the Squeegee Assembly to the required position 3 Tighten the Squeegee Assembly mounting hardware items 1 amp 3 To adjust the Front Wheel Brush 1 Loose the Front Wheel Brush mounting hardware 2 Position the Front Wheel Brush to the required position 3 Tighten the Front Wheel Brush mounting hardware NOTE The Left and Right Side Front Wheel Brushes Are Different Parts 22 IV PAR
10. 3 4 SELF DRILLING ROUND HD GROMMENT GC55 SWITCH EMERGENCY STOP GC55 SWITCH PANEL GC55 SCR X 8 0 7 DIN966 PHILIPS WASHER LOCK M4 DIN127 WASHER LOCK M8 DIN127 WASHER LOCK M6 DIN127B DIAMOND BLADE CONTACT CUSTOMER SERVICE KNOB W THREADED HOLE M10 X 1 5 X 50mm DIA SCR M8 X 40 1 25 DIN933 SCR M6 X 14 1 0 DIN933 SCR M8 X 30 1 25 DIN933 SCR M8 X 25 1 25 DIN933 HHC FULL THD NUT M8 1 25 DIN934 HEX PIN CLEVIS 9 5MM D X 11L 6 9MM USABLE LG HAIR PIN COTTER 1 4 TO 1 2 DIA X 0 062 X 1 5 16L SEE CUTTING HEAD ASSEMBLY PAGE 25 COLLAR LOCK GC55 SCR M6 X 30 1 0 DIN912 SOCKET HEAD HEX SCR M6 X 20 1 0 DIN912 SOCKET HEAD HEX PULLEY 70MM D X 3 4B 6G J SECTION KEY 3 16X3 4 34 Qty HSH Ha mm SB IJ HAH AH CO O OI a 1 Part No NA 241052 NA 27539 232110 241011 360146 235136 241041 241054 241055 241091 241092 241056 241057 241058 241059 241060 235099 241030 300245 300279 Contact Customer Service 241061 235009 241062 241063 300323 300273 241064 241065 241067 241068 241069 241070 9201074 Item 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Main Assembly GC55 DESCRIPTION SCR M5 X 10 0 8 DIN916 CUP POINT SET PULLEY 56 5MM D X 3 4B 6G J SECTION BELT 350J6 J SECTION 6 GROOVE SEE FRONT POINT ASSEMBLY GC55 GC2E PAGE 32 BELT GUARD GC55 SEE BLADE G
11. 32 813mm 32 813mm Width 18 1 8 460mm 18 1 8 460mm Height 42 23 32 1 090mm 42 23 32 1 090mm Frame Width 18 1 8 460mm 18 1 8 460mm Pointer Length 8 7 32 209mm 8 7 32 209mm Blade To Wall 7 1 2 190mm 7 1 2 190mm Wheel Base Length 19 483mm 19 483mm Blade Shaft Maximum Height 9 41 64 245mm 9 41 64 245mm Weight Created 135 lbs 61 kg 155 165 71 kg Weight Uncreated 115 Ibs 52 kg 135 lbs 61 kg Power Source Engine Motor Mfg Honda Gangfon Motor Spec No GX160K1QXC Totally Enclosed Air Cooled Thermal Protection Power Source Single Cylinder 4 Cycle Gasoline Electric Maximum Horse 5 5 HP 4 1 kW 2 1 2 HP Net Horse Power Max Torque Power Source RPM 3 600 RPM 3450 RPM Model Cooling System Oil Capacity Fuel Capacity Fuel Type Low Oil Sensor Air Filtration Voltage 115 230 volts Cycles Current Phase NA 60Hz AC 1 Full Load Amps 115 230 volts NA 15 7 5 Amps Starting Amps 115 230 volts NA 45 22 5 Amps Displacement 9 9 in 0 161 NA Bore x Stroke 2 7 68mm x 1 8 45mm NA Starter Manual Capacitor Characteristics Max Blade 10 254mm 10 254mm Depth of Cut 10 254 mm 3 5 88mm 3 5 88mm 8 203 mm 2 5 63mm 2 5 63mm Arbor Bore 5 8 5 8 Blade Shaft Flange Diameter 3 5 64 78mm 3 5 64 78mm Blade S
12. 5 and GC25E many advantages over the competitors machines such as a lower investment for our customer Use For Cutting Multiple Applications Green Concrete Early Entry Decorative Concrete Cured Concrete Asphalt Features that make the GC55 and GC25E a High Performance Multiple Applications Saw e Blade in center line of saw helps to reduce tearing of concrete when cutting green concrete The center line blade also helps the GC55 and GC25E to roll straight while cutting due to the blade being parallel to the blade e Reinforced all steel frame reduces bending flexing and vibrations which can damaged the concrete The reinforced all steel frame is also stronger than the competitive models e Soft Silicone Rubber wheels that are based off of a Norton Patient to absorb vibrations that can create spalling and machine movement The wheels also feature a concave profile that helps the machine to roll over small objects with out upsetting the blade e 10 maximum blade capacity with standard 5 8 arbor The GC55 and GC25E can use with 7 to 10 diameter Norton blades e Hand Wheel with Depth Adjustment Screw amp Depth Allows precise depth adjustments up to 3 1 2 deep when used with a 10 blade e Fully adjustable non scratching Dust removal system helps stabilize the GC55 and GC25E by pushing debris way from wheels and undercarriage of the machine Front and rear pointers for precise alignment Handle Bar and Pointer folds u
13. ER SVVITCH GC25E PANEL POVVER SVVITCH GC25E SCR X 8 0 7 DIN966 PHILIPS VVASHER LOCR M4 DIN127 VVASHER LOCR M8 DIN127 VVASHER LOCR M6 DIN127B DIAMOND BLADE CONTACT CUSTOMER SERVICE KNOB W THREADED HOLE M10 X 1 5 X 50mm DIA SCR M8 X 35 1 25 SHCS DIN7991 SCR M6 X 14 1 0 DIN933 SCR M8 X 30 1 25 DIN933 SWITCH TOGGLE POWER 20A PIN CLEVIS 9 5MM D X 11L 6 9MM USABLE LENGTH HAIR PIN COTTER 1 4 TO 1 2 DIA x 0 062 x 1 5 16L SEE CUTTING HEAD ASSEMBLY GC25E PAGE 25 COLLAR LOCK GC55 SCR M6 X 30 1 0 DIN912 SOCKET HEAD HEX SCR M6 X 20 1 0 DIN912 SOCKET HEAD HEX PULLEY 70MM D X 3 4B 6G J SECTION SCR M5 X 10 0 8 DIN916 SET CUP POINT PULLEY 56 5MM D X 3 4B 6G J SECTION BELT 350J6 J SECTION 6 GROOVE SEE FRONT POINT ASSEMBLY PAGE 27 BELT GUARD GC55 BLADE GUARD ASSEMBLY GC55 RETAINING RING C STYLE 60mm X 2 0mm DIN471 ARM STAY LEVEL GC55 37 Qty FS O No EB qnl Part No 241041 241054 241055 241091 241092 241056 241057 241058 241104 241105 235099 241030 300245 300279 241061 241106 241062 241063 235165 241064 241065 241067 241068 241069 241107 241027 241071 241072 241073 241074 241075 241076 241078 Item 46 47 48 49 50 51 52 53 54 55 58 59 60 61 DESCRIPTION SPACER M14 CAM STAY LEVEL GC55 LOOSE COLLAR GC55 TIGHT COLLAR GC55 NUT 5 8 11 UNC HEX LEFT HAND THREAD
14. EX HEAD CAP SCR M8 X 65 1 25 DIN931 HEX HEAD CAP SCR M8 X 35 1 25 SOCKET HEAD CAP DIN912 BRUSH WHEEL OPERATOR S RIGHT GC55 SQUEEGEE ASSEMBLY ONLY GC55 POWER CABLE SUPENSION ARM GC25E SCR 4 X 8 0 7 DIN966 PHILIPS CHAIN FOR QUICKRELEASE PIN 9 LONG GC55 WASHER LOCK M4 DIN127 PIN QUICKRELEASE 5 16 X 2 GRIP LENGTH FRONT AXLE GC55 BRUSH WHEEL OPERATOR S LEFT GC55 31 N N Part No 241101 241040 241039 232110 235104 241041 241042 241058 241044 241045 300245 235013 235103 241040 241047 241048 241050 241102 235099 241056 241030 241092 241046 241049 Front Pointer Assembly GC55 and GC25E Item DESCRIPTION Qty Part No 1 POINTER WELDMENT GC55 GC25E 1 241085 2 WHEEL 75X28X8mm 1 241086 3 FRONT POINTER ROD GC55 GC25E 1 241087 4 WASHER M8 DIN125 FLAT 2 232110 5 NUT M8 1 25 LOCK DIN985 2 241041 32 Main Assembly GC55 33 24 25 26 27 28 29 30 31 32 33 34 35 36 3 Main Assembly GC55 DESCRIPTION SEE FRAME ASSY GC55 PAGE 30 HANDLE BAR GC55 ENGINE ASSEMBLY GC55 SEE PAGE 28 WASHER M6 DIN125 FLAT WASHER M8 DIN125 FLAT SCR M6 X 55 1 0 DIN933 HEX HEAD CAP SCR M8 X 60 1 25 DIN933 HHC FULL THD NUT M6 DIN985 LOCK NUT M8 1 25 LOCK DIN985 SCR 5 16 18 UNC X 2 1 2 CARRIAGE BOLT WASHER 3 8 WAVE KNOB M8 X 1 25 ADJUSTABLE PIN QUICKRELEASE 5 16 X 2 GRIP LENGTH CHAIN FOR QUICKRELEASE PIN 9 LONG SCR NO18 18 X
15. OWNERS MANUAL Multiple Application Concrete Saw MODEL GC55 and GC25E FORM GC55 GC25E rev 4 2010 LLL ope VVARRANTY Norton vvarrants all products manufactured by it against defects in workmanship or materials for a period of one 1 year from the date of shipment to the customer The responsibility of Norton under this warranty is limited to replacement or repair of defective parts at Norton s Stephenville Texas factory or at a point designated by it of such part as shall appear to us upon inspection at such point to have been defective in material or workmanship with expense for transportation borne by the customer In no event shall Norton be liable for consequential or incidental damages arising out of the failure of any product to operate properly Integral units such as gasoline engines electric motors batteries tires transmissions etc are excluded from this warranty and are subject to the prime manufacturer s warranty This warranty is in lieu of all other warranties expressed or implied and all such other warranties are hereby disclaimed Important Before placing equipment in operation record the following information MODEL SERIAL NO PURCHASE FROM ADDRESS CITY STATE ZIP TELEPHONE NO Before using this equipment make sure that person using it read and understand the instructions in this owner s manual A warne AN The engine exhaust from this product contains chemica
16. TS LIST SECTION A Ordering Information 1 List model number and serial number of machine 2 List part number and serial number of part not the item number 3 Wherever alternate parts are shown due to product improvement inspect the part you have and provide additional description as necessary 4 Specify mode of shipping desired such as parcel post truck U P S best way etc For the nearest Clipper distributor call 1 800 554 8003 Common Replacement Parts Description PatNumber _ WHEEL 75X28X8mm NOTE All Parts Are Sold As Individual each Unless Noted Otherwise Blades Use Only Norton Diamond Blades Contact your local Norton Clipper Distributor or Norton Clipper at 1 800 554 8003 for the best blade for the application 23 Item CO AN O O gt Blade Guard Assembly GC55 and GC25E Description GUARD BLADE GC55 GC25E BLADE SHAFT VENT COVER VVASHER M6 DIN125 FLAT SCR M6 X 16 1 0 DIN933 SCR M6 X 12 1 0 DIN933 NUT M6 DIN985 LOCK SCR THUMB M6 X 12 1 0 SPLASH GUARD GC55 GC25E 24 Q Part No 241001 241002 27539 235048 300566 235136 241003 241004 Cutting Head Assembly GC55 and GC25E DESCRIPTION BEARING CUTTING HEAD SUB ASSY SEE PG 23 FOR PARTS PULLEY IDLER TENSION ADJUSTER SPACER INDLER GC55 GC25E PULLEY IDLER ASSEMBLY GC55 GC25E ZERK FITTING M6 SCR M12 X 80 1 75 DIN933 SCR 8 X 25 1 25 DIN933 FULL THD SCR M6 X 55 1 0 DIN933 SCR M6 X 30 1 0
17. UARD ASSEMBLY GC55 GC25E PAGE 24 RETAINING RING C STYLE 60mm X 2 0mm DIN471 ARM STAY LEVEL GC55 GC25E SPACER M14 CAM STAY LEVEL GC55 GC25E LOOSE COLLAR GC55 GC25E TIGHT COLLAR GC55 GC25E NUT 5 8 11 UNC HEX LEFT HAND THREAD SEE DEPTH CONTROL ASSEMBLY GC55 GC25E PAGE 27 WASHER M6 DIN 125 FLAT WRENCH UNIVERSAL KEY 3 16X1 1 4 SPACER SHAFT GC55 GC25E WASHER M8 DIN125 FLAT WASHER M8 DIN125 FLAT 35 Qty A l l 1 o lA Part No 241027 241071 241072 NA 241074 NA 241076 241078 241079 241080 241081 241082 241083 NA 2 539 233041 9201080 241088 232110 232110 Item OC OI CO Main Assembly GC25E DESCRIPTION SEE FRAME ASSEMBLY GC25E PAGE 31 HANDLE BAR GC55 SEE MOTOR ASSEMBLY GC25E PAGE 29 WASHER M6 DIN125 FLAT WASHER M8 DIN125 FLAT SCR M10 X 60 1 5 DIN931 SCR M8 X 60 1 25 DIN933 HHC FULL THD NUT M6 DIN985 LOCK 36 Part No NA 241052 NA 27539 232110 27030B 360146 235136 Item 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 31 2 33 34 35 36 38 39 40 41 42 43 44 45 DESCRIPTION NUT M8 1 25 LOCR DIN985 SCR 5 16 18 UNC X 2 1 2 CARRIAGE BOLT VVASHER 3 8 VVAVE RNOB M8 X 1 25 ADJUSTABLE PIN QUICRRELEASE 5 16 X 2 GRIP LENGTH CHAIN FOR QUICRRELEASE PIN 9 LONG GC55 SCR NO18 18 X 3 4 SELF DRILLING ROUND HEAD GROMMET GC55 SHIELD POVV
18. ate than the concrete below The concrete needs to cure to a deeper depth in order to prevent the shell chipping Ill MAINTENANCE A Engine GC55 Follow the below schedule for engine maintenance NOTE Check the Honda Engine manual that came with the engine for any changes to the maintenance schedule If the charts have any differences follow the chart in the Honda Engine Manual The Norton Company does not warranty the engine If any warranty or service of the engine is required contact your nearest Honda nearest Honda service center or from the Internet http www honda engines com home htm Honda engine Refer to owner s manual for complete maintenance MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD Perform at every indicated operating hour interval Engine oil foy Check level Change Reduction gear oil Check level _ Change Air cleaner Clean Fuel strainer cup Clean Spark plug Check Clean Valve clearance J 351 Combustion chamber and valves Clean Lap d 934 Fuel line Check Every 2 years 3 Replace if necessary yey NOTE 1 Service more frequently when used in dusty areas Check the engine oil level before each use when the engine is cool and the engine is level Add oil if the level is low The oil level should be within the operating range See the engine owner s manual for details Only use a high detergent premium quality motor oil certified
19. ay stall the saw or ruin the cut e lf the saw stalls in the cut immediately stop the forward speed and raise the blade out of the cut If this is not done the belts can fail or the blade may be damaged e Goslowly with a new blade until it opens up that is until the diamonds can be seen and felt E Green Concrete Cutting The new Norton Clipper GC55 and GC25E are much more than a green concrete saw or as it is some times called an early entry saw The GC55 and GC25E where designed from the ground up to be a High Performance Multiple Application saw The GC55 and GC2E models are capable of cutting Green Concrete Early Entry Cured Concrete Asphalt and Decorative Concrete Being able to cut more than just green gives the GC55 and GC25E many advantages over the competitor s machines such as a lower investment for our customer Green Concrete Cutting Important Considerations Green concrete is concrete that is still in a plastic state that is the concrete still has a lot of moisture in it in other words it is not fully cured or dry As the concrete starts to hydrate Dry or Cure the concrete will change slightly in volume Concrete normally shrinks about 1 16 for each 10 feet during the hydration process This change in size creates internal stress in the concrete which will develop into cracks Joints also known as Crack Control Joints and or Expansion Joints are normally cut into the concrete in order to relieve the internal stress
20. carefully mark a line 12 feet long on a smooth level surface Place the saw blade on the marked line move the saw to the center of the marked line and then lower the blade until it is about 1 16 above the marked line Measure from each end of the saw frame to insure that the frame is parallel to the marked line Adjust the saw as needed With the blade centered on the marked line and the saw frame parallel to the marked line lower the front pointer Adjust the nylon nuts until the pointer is aligned with the marked line 10 E Electrical Connections GC25E Important Before connecting the motor leads to the be sure that the voltage cycles and phase shown on the nameplate of the motor correspond to the available power supply Voltage Selection for the GC25E 3 HP motor is single phase saw motors witch have a dual voltage capable Either a 115 volt or 230 volt power supply can be used To change voltage simply move the voltage change switch located on the front of the motor to the required voltage no rewiring is required Wherever possible use 230 volt power supply for best operation Failure to run the motor on the proper voltage will damage the motor and is not covered under warranty Improperly wired motors are not covered under warranty The GC25E models are wired for 115 Volt from the factory Power Connections Connect the power supply to the pigtail leads of the switch Direct wiring connect
21. ed over the arbor with the drive pin on the outside collar projecting through the drive pin hole on the blade and inside collar The blade shaft nut which is a left hand thread nut must be tightened securely against the outside blade shaft collar The blade must be operated within the specified maximum operating speed listed on the blade The blade guard must be in place with the nose guard down and locked when the saw is running The operator should wear safety glasses and any other appropriate safety equipment When starting the saw the operator should stand away and to the side of the blade If for any reason the saw should stall in the cut raise the blade out of the cut Check the outside blade shaft collar and nut for tightness Inspect the blade for damage before restarting the saw Use caution when resuming a cut Be certain that the blade is in alignment with the previous cut 10 During cutting operations do not exert excess side pressure on the handles as a method of steering Do not force the blade into the cut by lowering the blade too fast or by pushing the saw too fast You Are Responsible For Your Safety PREPARATION B Assembly The GC55 and GC25E compact concrete saws are shipped completely assembled and ready for use except for diamond blade gasoline oil and Handle Bar position for the GC55 and diamond blade electrical extension cord and power supply for the GC25E Inspect the saw for s
22. en green concrete cutting Factors that affect the concrete set up are a Concrete Mixture PSI concrete type sand type and amount and other materials b Water to Cement Ratio more water the longer the set up C Aggregate Size and Type d Concrete Additives some speed up while others slow down the set up time e Environmental Factors Sun Wind Rain Temperature f Concrete Temperature cooler the concrete the longer the set up time 2 Flat surface Flat surfaces help to insure that the blade is perpendicular to the concrete which reduces the chances of damaging the concrete 16 surface When the blade meets the concrete surface at a 90 angle perpendicular less side drag is created on the blade When the blade is not perpendicular side drag is create that will cause the concrete to chip or spall 3 Blade that is designed for green concrete cutting The GMAX blade has some unique features that make it an outstanding blade for green concrete cutting such as a Anchor Slot Core Technology that reduces vibrations in the blade Excessive vibrations will cause the blade to flutter or bend from side to side which will damage the concrete surface and cause the blade to wear out prematurely b Thicker core that resist flexing and bending Thin core blades bend due to excessive pressure during cutting and from over heating When blade bends and flexes the concrete and blade will be damaged C Optimized bond and
23. haft Speed 2905 rpm 2905 rpm Depth Control Hand Wheel With Screw Feed Hand Wheel With Screw Feed Depth Lock Standard Standard Depth Gauge Standard Standard Number Of V Belts 1 1 Blade Guard Type Screwed On All Steel Construction Screwed On All Steel Construction Cutting Side Center Center Lifting Bale Built In Built In Handle Bars Adjustable Stays Level At All Times Adjustable Stays Level At All Times Wheels Non marking Non marking Wheel Size Front and Rear 3 3 8 x2 3 4 x25 32 85x70x20mm 3 3 8 x2 3 4 x25 32 85x70x20mm Sound pressure 88 db A NA Sound power 105 db A NA 1 Net Horsepower Rating provided by engine the manufacturer measured in accordance to SAE j1349 3 600 RPM The engine may vary from this value Actual horsepower on the machine will vary due to operating speed of engine belt tension environmental conditions machine maintenance and other variables 2 Starting Amps are instantaneous for best results use with a 30Amp circuit 3 The sound measures have been made following pr EN 12638 Annex A 2 Floor sawing grooving and milling machines Safety The GC55 and GC25E concrete saws where designed from the ground up to be a High Performance Multiple Application saw The GC55 and GC25E are capable of cutting Green Concrete Early Entry Cured Concrete Asphalt and Decorative Concrete Being able to cut more than just green gives the GC5
24. hipping damage If any damage is found contact the shipper immediately and file a freight claim Saint Gobain Abrasives Inc is not responsible for any freight related damages Adjust the Handle Bars Position 1 Remove the GC55 GC25E from the box 2 Remove the Quick Release Pin P N 241055 out of it s retaining hole 3 4 Rotate the Handle Bar from the lowered storage position to the desired Loose the Black Knob P N 241054 position Align the hole in the Handle Bar with the holes in the frame 6 Attach the Quick Release Pin P N 241055 by pushing it through the 7 hole in the Frame and then the hole in the Handle Bar Make sure that the Quick Release Pin passes all the way through both sides of the Frame Tighten the Black Knob P N 241054 Read and understand the remaining sections of this Owner s Manual NOTE Do not install the blade until it is time to use the saw ANSI regulations prohibit the transportation of any concrete saw with the blade installed Part Description Q 241054 SCR 5 16 18 UNC X 2 1 2 CARRIAGE BOLT 241055 PIN QUICKRELEASE 5 16 X 2 GRIP LENGTH 241054 KNOB M8 X 1 25 ADJUSTABLE 232110 WASHER M8 DIN125 FLAT 241055 WASHER 3 8 WAVE C GC55 and GC25E Series Concrete Saw Specifications Dimensions Weight GC55 GC25E Length Working 42 23 32 1 090mm 42 23 32 1 090mm Length Transport
25. ion is preferred but an extension cord with an electrical plug with 30 amp minimum capacity may be used A 30 amp circuit breaker is recommended Connecting wires should be as short as possible and in one piece In no case should the connecting wires be longer than shown in the following table for use with the GC25E Single phase motors Length Of Wire Wire Gauge Caution When wires that are too small gauge or too long are used loss of power over heating or possible damage to the motor will result Damage or failure of motors due to incorrect power supply cord lengths are not covered under any warranty Number 08 Always use the proper wiring connectors that are UL CSA approved to attach the motor to the electrical supply Any wiring hook ups should be made by qualified personal and made to National Electrical Code and to any Local Codes Generators If a generator must be used it must be of 8kW or larger The generator must have a 30A circuit and capable of providing a minimum of 8kW at the required voltage Under size generators will cause motor damage and is not covered under warranty Green n a Black Black a s __ white 15Vv 230V Switch AH White Pawer Switch Box Wiring Diagram GC2E Only Thermal Reset If the thermal reset engages this is a sign that
26. ls to the State of California to cause cancer birth defects or other reproductive harm Table Of Contents CONTENTS Preparation A Safety Precautions B Assembly C GC55 and GC25E Series Concrete Saw Specifications D Engine GC55 Models E Electrical Connections GC25E Wiring Diagram GC25E Il Operation A Installing The Blade B Starting The Engine GC55 C Operating The Saw D Cutting Technique E Green Concrete Cutting lll Maintenance A Engine B Bearings C V Belts D Depth Control E Dust Removal System Adjustment IV Parts List Section A Ordering Information B Parts Drawing Service Parts List Blade Guard Assembly GC55 and GC25E Cutting Head Assembly GC55 and GC25E Blade Shaft Assembly GC55 and GC25E Depth Control Assembly GC55 and GC25E Engine Assembly GC55 Only Motor Assembly GC25E Only Frame Assembly GC55 Only Frame Assembly GC25E Only Front Pointer Assembly GC55 and GC25E Main Assembly GC55 Only Main Assembly GC25E Read Owners Manual Before Use Safety Alert Symbol Information Following This Symbol Is Very Important Use Only Norton Diamond Blades PREPARATION A Safety Precautions Important The following safety precautions must always be observed Hazard Symbols Fuel gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied approved areas and away from sparks or flames Do not fill the
27. m VVASHER LOCR M4 DIN127 SCR M4 X 16 0 7 DIN933 DEPTH CONTROL POINTER BAR GC55 GC25E KNOB W THREADED HOLE M6 X 15 1 0 27 Qty lt lt _ cl c 241090 241019 241020 241021 241022 241023 9201074 241024 241025 241026 241027 241028 241029 241089 241030 235057 241031 241032 llw AREAS Ds Engine GC55 Only Part No Qty DESCRIPTION Item 216264 241033 ENG 5 5HP HONDA 1 2 4 SCR M5 X 12 0 8 FLAT HEAD SOCKET CAP 2 3 4 5 6 241034 241035 241036 SCR 5 16 24 UNF X 3 4 C SINK SOCKET HEAD OIL DRAIN HOSE ASSY 5 5HP HONDA BRACKET SELF LEVELING MOUNT GC55 CUTTING HEAD FLANGE GC55 241037 28 Motor Assembly GC25E DESCRIPTION MOT 2 5HP 115 230v 60 1 GC25E COMPLETE MOTOR ITEMS 2 to 21 COVER FAN GG25E GASKET RUN CAPACITOR COVER GC25E COVER RUN CAPACITOR GC25E GASKET START CAPACITOR COVER GC25E COVER START CAPACITOR GC25E BOX VOLTAGE CHANGE SWITCH GC25E TOGGLE SWITCH GC25E CABLE GLAND PG 11 GUARD SWITCH GC25E CAPACITOR RUN GC25E CAPACITOR START GC25E SCR 10 24 X 3 8 PHILLIPS ROUND HEAD SCR M5 X 40 0 8 DIN7985 PH PHILLIPS SCR M5 X 40 0 8 DIN7985 PH PHILLIPS NUT M5 0 8 LOCK DIN985 FAN GC25E WASHER M4 DIN125 FLAT NUT M4 0 7 DIN934 SCR 10 24 X 3 8 PHILLIPS ROUND HEAD SCR M6 X 16 1 0 DIN7985 PH PHILLIPS SCR 10 24 X 1 4 PHILLIPS ROUND HEAD 29 Qty CEE
28. n These types of bearings are designed for long life and minimum maintenance If any problem occurs with the blade shaft or wheel bearings replace the bearing The only the Raise Screw and Cutting Head pivot point will need periodic re lubrication Both of these points require just a squirt of a good quality NLGI 2 aluminum complex type grease is recommended one time a month Check the function of the Hand Wheel and Cutting Head before each use Lubricate the Raise Screw and Cutting Head pivot point once a month or when the it becomes hard to turn the Hand Wheel C V Belts Warning Never make adjustments to belts or pulleys while engine is running 1 The best tension for a belt drive is the lowest tension at which the belts will not slip under full load 2 Simply take up the drive until the belts are snug in the grooves Run the drive for about 15 minutes to seat the belts Then impose the peak load If the belts slip tighten them until they no longer slip at peak load 20 3 Remember too much tension shortens belt and bearing life 4 Check the belt tension frequently during the first day of operation Check the belt tension periodically thereafter and make any necessary adjustments 5 The two most common causes of misalignment are shown in the Figure 1 and Figure 2 to the right a The engine drive shaft and the blade shaft are not parallel b The pulleys are not located properly on the shafts 6 To check alig
29. nment all you need is a steel straight edge 7 Line up the straight edge along the outside face of both pulleys as shown in the drawing FIGURE 1 FIGURE 2 8 Misalignment will show up as a gap between the pulley face and the straight edge 9 Make sure that the width of the outside land Area between the belt and the edge of the pulley is equal on both pulleys D Depth Control The cutting depth is controlled by a chrome turn handle It is located next to the push handle base easily accessible from the rear of the saw The handle must first be unlocked before it can be turned It is locked by a black knob located on the operator s left side of the hand wheel near the base of the handle This knob must be turned counter clockwise to unlock the handle Once unlocked rotating the handle clockwise will lower the cutting blade Rotating it counter clockwise will raise the cutting blade When the proper cutting depth is achieved by reading the depth gauge relock the turn handle to ensure a constant cutting depth throughout the cut The depth gauge can be found further down the shaft of the turn handle This gauge will already be preset for an 10 blade but it still must be calibrated by the user since blade diameters may vary When using an 8 blade the gauge must be readjusted from an 10 blade to an 28 blade Simply loosen the black knob found near the collar of the gauge and slide it accordingly to achieve the proper reading 2
30. p for compact easy transport Light in weight the GC55 weights only 115 Ibs The GC55 and GC25E are very simple machines to operate The GC55 and GC25E are designed for cutting Multiple applications Green Concrete Early Entry Cured Concrete Asphalt and Decorative Concrete e Includes a free 10 GMAX blade The GMAX blade is specifically designed with the following features for improved Green Concrete cutting o Anchor Slot Core Technology Reduces Chip Causing Vibrations o Thicker Core Resist Flexing and Bending For Improved Cut Quality o Optimize Bond And Diamond For Fast Green Concrete And Aggregate Cutting D Engine GC55 Models Prior to attempting to operate the engine read the information contained in the engine owner s manual An engine owner s manual is supplied with every gasoline powered concrete saw 1 Check Oil Add oil if low Refer to the engine owner s manual for the recommended SAE viscosity grades Capacity of oil is 0 6 liter 0 63 US qt Check Fuel Fill if low Use only unleaded gasoline with a pump sticker octane rating of 86 or higher is recommended Never use an oil and gasoline mixture Air Cleaner Never run the engine without the air cleaner Rapid engine wear will result from contaminants being drawn through the carburetor and into the engine Engine Starting Refer to the engine owner s manual for proper engine starting procedure Pointer Alignment Use a straight edge and
31. s and or material being cut or the composition of the tool being used review the material safety data sheet and or consult your employer the material manufacturer supplier governmental agencies such as OSHA and NIOSH and other sources on hazardous materials and make certain to comply with all product warnings and instructions for the safe and effective use of the material being cut California and some other authorities for instance have published lists of substances known to cause cancer reproductive toxicity or other harmful effects Control dust mist and fumes at the source where possible In this regard use good work practices and follow the recommendations of the manufacturer supplier OSHA NIOSH and occupational and trade associations Water should be used for dust suppression when wet cutting is feasible When the hazards from inhalation of dust mists and fumes cannot be eliminated through engineering controls such as vacuum and or water mist the operator and any bystanders should always wear a respirator approved by NIOSH MSHA for the material being cut Use Approved Eye Protection Hearing Respiratory Head Protection Protection Protection Before mounting any blade on the savv the blade should be inspected for any damage which might have occurred during shipment handling or previous use The blade collars and arbors should be cleaned and examined for damage before mounting the blade The blade must be properly fitt
32. slide the blade under the blade guard at an angle will simplify the installation process Be careful not to hit the blade shaft with the blade Locate the blade shaft then slide the blade bore hole onto the blade shaft Use only Norton Diamond Blades This machine was not designed for the use with abrasive blades For the best performance when cutting green concrete use the Norton GMAX series blade Slide the outside blade shaft collar onto the blade shaft Tighten the blade shaft nut Turn counter clockwise securely against the outside collar Close the blade nut access door Reconnect the spark plug GC55 models only Use Only Norton Diamond Blades Starting the Engine GC55 Refer to the engine owner s manual for the proper starting procedures Always cut with engine rpm in the full throttle setting Operating the Saw For blade installation instructions see section Operation sub heading A Installing the Blade For the engine starting instructions GC55 see the Engine manual and follow the instructions located in section Operation sub heading B Starting the Engine and for Electrical Connections GC25E see section E Electrical Connections GC25E Check the Engine Oil level GC55 only Raise the saw to the full upright position Do not let the blade come in contact with the ground Maneuver the saw to the desired starting point 5 To start the machine a GC55 Follow the instructions for star
33. the motor is over heating Continued over heating will damage the motor The thermal reset will reset it s self once the motor is cooled Do not force the thermal reset as it will damage the reset and motor The causes of the thermal reset activating are 1 Too Long or Too Thin of Extension Cord Low Voltage Use the correct length and gauge of Extension Cord 2 Low Voltage Power Supply Use a power supply with the correct voltage 3 Incorrect Blade of Application Contact Norton Clipper s customer service or your local sales person for the correct blade specification for your cutting application 4 Overloading Machine At a shallower depth Make multiple passes Step Cutting at no more than 1 1 4 deep Cut ata slower forward speed Damage or failure of a motor due to continued over heating as the result of incorrect extension cord length size incorrect power supply incorrect application and continued overloading is not covered under warranty Il OPERATION A Installing the Blade 1 Disconnect the spark plug GC55 Models Only 2 Raise the Blade Guard to its highest position 3 Open the blade nut access door Remove the blade shaft nut Turn clockwise and remove the outside collar and raise the Blade Guard 12 Clean off any foreign particles on the clamping surfaces of both collars and on the mounting surface of the blade Position the blade beneath the cutting head and slide the blade into the blade guard
34. ting the engine found in the Engine manual Verify that the emergency stop switch is in the up position Turn Engine On Off Switch to the on position Turn the Fuel Control to the On position Engage Choke as necessary V Pull start rope If the engine does not start within 3 5 pulls of the start rope refer to the engine owner s manual for more information b GC25E For Electrical Connections Extension Cord Set Information and Generator Information see section E Electrical Connections GC25E vi Verify that the motor voltage change switch is set to the same voltage as the circuit Verify that the circuit has a 30 Amp breaker installed Verify that the extension cords are the correct gauge length and are properly grounded Verify that the GC25E power switch in the off position connect the extension cord set to the machine and power supply Follow all local and national electrical code If unsure of how to connect the extension cord set or of the electrical circuit have a qualified Electrician make all electrical connections Move the start switch to the On position and the motor should start If the motor doe not start have a qualified Electrician inspect all electrical connections and the power supply 6 For the GC55 be sure the engine is running at full throttle 7 Slowly lower the blade by rotating the hand wheel clockwise until the desired depth of cut is reached Use a reasonable rate of feed Do not force the blade
35. to meet or exceed U S automobile manufacturer s requirements for Service Classification SG SF CC CD Motor oils will show the classification on the container A SAE viscosity of 10W 30 is recommend by Honda for general all temperature use Please consult the below chart or contact your local Honda service center for the proper viscosity for your temperature range 30 20 10 30 40 19 Always refer to the engine manual for more detailed information on checking the oil changing oil and oil capacity air filter changes and fuel type to use Use only Honda air filters Do not clean the air filter with gasoline or other flammable solvents A fire or explosion could result To clean follow the instructions found in the Honda engine manual Dry Cutting Engine Maintenance e When operating the engine in dry cutting or dusty environments the following is required e Engine oil changed more often e Every 50 hours or more often if conditions require clean all of the engine cooling fins e Every 25 hours or more often if conditions require clean the engine pre cleaner e Every 100 hours or more often if conditions require replace the air filter If the engine is equipped with a reusable air cleaner clean and re oil it Check and clean the air filter after each use Replace as needed B Bearings The GC55 and GC25E are equipped with permanently sealed blade shaft and wheel bearings that will never need any lubricatio
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