Carat Caracoup 104 Tile Saw Machine Instruction Manual (+ PDF)

Contents hide

1 CARAT CARACOUP 104 Tile Saw Machine

2 GENERAL

7 Documents / Resources

7.1 References

CARAT CARACOUP 104 Tile Saw Machine

GENERAL

Operating manual
This operating manual provides guidance on safe and efficient operation and should form a basis of any actions involving the machine. It is an integral part of the machine, which should be kept in the immediate vicinity accessible for its operating personnel. Prerequisite of safe operation is adherence to all safety and handling instructions. Therefore, before starting any work, the personnel must read carefully and understand the operating manual. Moreover, the accident prevention regulations applicable at the site of the machine operation and general safety regulations must be complied with.

Explanation of symbols

Warnings and safety instructions
Warnings and safety instructions in the manual are identified with the pictograms and provided in blocks highlighted in grey.

DANGER
draws attention to an immediate danger that, if not avoided, may result in heavy or even fatal injuries.

ATTENTION!

draws attention to potentially dangerous situa-tions that, if not avoided, may result in material damage.
marks danger due to electric current.
Failure to observe the safety instructions leads to danger of heavy or fatal injuries.
marks danger of crushing.
Failure to observe the safety instructions leads to danger of heavy injuries from moving parts.
marks danger due to hot surface.
Failure to observe the safety instructions leads to danger of burns and heavy skin injuries caused by heat.
marks danger from moving diamond blades. Failure to observe the safety instructions leads to danger of cuts and heavy skin injuries caused by rotating diamond blades.

Liability limitation
All data and instructions provided in this manual were compiled with consideration of applicable standards and regulations, state of the art in this field and our long-standing insights and experience. The manufacturer accepts no liability for damages caused by:

Non-observance of the Operating manual.
Unintended use.
Employment of unskilled and uninstructed personnel.
Unauthorized conversions.
Technical changes.
Use of non-approved spare parts.

The responsibilities agreed in the delivery contract, the General Terms and Conditions as well as the delivery conditions of the manufacturer and the statutory regulations valid at the time of the conclusion of the contract shall apply.

Warranty
The manufacturer guarantees the functional capability of the applied process technology and performance parameters identified. The warranty period commences with the defect-free delivery.

Warranty conditions
12 months after delivery of mechanical and electrical components for one-shift operation, except for the worn parts and tools. The warranty claim expires, if the system was not installed and started up by our experts. The warranty extends to the replacement parts. Consequential damages are excluded. Damage caused by natural wear, deficiency of improper maintenance, failure to comply with the operating regula-tions, excessive loads and use of inappropriate equipment shall be excluded from the warranty.

SAFETY

Intended use
The CARACOUP 60 / CARACOUP 104 tile cutting machine is designed exclusively for the following purposes in the commercial sector: is designed for wet cutting of the solid construction materials such as: Tile, ceramic and marble

Any claims for damages resulting from unintended use are excluded.
The operator alone is responsible for all damages due to unintended use.

Rationally foreseeable misuse
Any use of the machine going beyond the intended one, shall be deemed unintended and thus prohibited.

This also applies to:

Cutting any materials other than presented.
Cutting without or with open diamond blade guard.
Cutting without water.
Removal of clippings in pendulum cutting procedure (vertical plunging into chippings from above).

Responsibilities of the operator

Operator
An operator is every natural or legal person, who uses the machine or delegates its use to others and is responsible for the safety of the user, personnel or third parties in the course of such use.

Operator’s duties
The machine is used in the commercial sector. Therefore, the operator of the machine is subject to statutory obligations regarding occupational safety.

The operator, in particular, must:

Be informed about current occupational safety regulations.
Determine, through hazard evaluation, any potential additional dangers resulting.
From specific usage conditions at the site of the machine operation.
Check regularly throughout the service life of the machine, whether the operating instructions drawn up by the operator are in line with the current status of rules and regulations.
Exercise control of the competence for installation, operation, maintenance and cleaning of the machine in a clear¬ and unambiguous manner.
Make sure that all personnel involved with the machine have read and understood the operating instructions. Moreover, the personnel must undergo training in handling the machine at regular intervals and be informed about potential dangers.
Provide the persons appointed for operating the machine with the prescribed and recommended protective devices.
Moreover, the operator is responsible for ensuring that the machine is always in a technically perfect condition.
Is maintained according to the specified maintenance intervals, and that all safety mechanisms of the machine are regularly controlled for completeness and functionality.

Personnel requirements

Fundamentals
Any operation with the machine may only be carried out by the persons, capable of performing their work properly and reliably and meet every requirement mentioned.

No works can be carried out by the persons, whose response capability is affected, e.g., by drugs, alcohol or medicines.
When deploying personnel at the site of operation, always adhere to the applicable occupational and specific regulations.

WARNING:
Risk of injury for unqualified personnel! Improper operation can result in significant personal and material damage. Any operations must be only carried out by the persons having required training, knowledge and experience.

Qualified electricians
As a matter of principle, all works on the electrical installations must be carried out by qualified electricians.

Personal protective equipment
Wearing personal protective equipment is required during the work.

Helmet with ear protectors.
Visor or protective goggles.
Dust mask / respirator.
Safety gloves.
Suitable protective clothing.
Protective footwear.

NOTE!
It is prohibited to wear protective gloves near rotating parts, which pose the danger of pinching. Here, danger created by wearing protective definitely surpasses the intended protection.

Dangers
The machine has undergone a risk review. Wherever possible, the identified dangers were eliminated and risks reduced. Nevertheless, the machine poses residual risks described in the following section.

Strictly observe warnings and safety instructions specified here and in the chapters about handling¬ to avoid potential damage to health and dangerous situations.

Risks

CAUTION! Risk of cut injuries!

Reaching into rotating tools may lead to heavy injuries.

Do not touch rotating diamond blades in any circumstances.
Never work without diamond blade guard.
Only work with diamond blade guard closed.
Only remove clippings with diamond blade stopped.

CAUTION!
Risk of injury by flying clippings or tool parts!

Failure to wear appropriate protective equipment, working with open diamond blade¬ guard or with inappropriate diamond blades may lead to heavy injuries.
Wear protective goggles.
Only work with diamond blade guard closed.
Only work with diamond blades, specifically designed for the material to be cut.

CAUTION!
Risk of injury by pinching in movable parts! Failure to wear appropriate protective equipment may lead to heavy injuries.

Wear protective gloves.
Lock the cutter head.
Lock the guiding bridge.
Always fix the cutting table with transport lock (for table saw machines).

DANGER!
Danger to life from electric current! Touching live parts leads to death. Damaged insulation or individual components can be life-threatening. Disconnect the machine from the power supply before any work on the electric system. Verify that the system is disconnected from power supply.

Switch off ¬power supply before maintenance, cleaning and repair operations and secure the machine against being restarted.
If the power supply insulation is damaged, switch off immediately and arrange for repairs.
Never bypass or disable fuses.
Always use fuses with correct amperage when replacing defective fuses.
Keep moisture away from live parts.
Any works on the electrical installations must be carried out by qualified electricians.

CAUTION! Risk of burns on hot surfaces.

Contact with hot parts may cause burns.
Do not touch the surface.
Before every work, make sure that the parts have cooled down to the ambient temperature.

CAUTION!
Danger of injuries caused by special physical effects Failure to wear appropriate protective equipment may lead to heavy injuries. Wear ear protectors. Wear protective gloves. Take adequate breaks. Regular medical examinations ‘G20‘.

CAUTION!
Risk of injury by hazardous substances, such as dust and cutting water or slurry! Failure to wear appropriate protective equipment may lead to damage to health. Use personal protective equipment. Renew the cutting water regularly. Use the dust mask. Connect water supply.

CAUTION!
Risk of injury due to inadequate lighting. Work in inadequate lighting conditions may lead to heavy injuries. Provide for adequate lighting at the workplace.

WARNING:
Danger to life due to defective or bypassed safety devices! Inoperable, bypassed or disabled safety devices do not protect from hazards and may lead to heavy or fatal injuries. Before commencement of works, always make sure that all safety devices are properly installed and functional. Never disable safety devices. Ensure that the safety devices are always freely accessible

WARNING:
Risk of injury due to wrong spare parts. Wrong spare parts can seriously compromise safety and cause damage and malfunction up to total failure. As a matter of principle, only original spare parts must be used. Original spare parts can be obtained via an authorized dealer or directly from the manufacturer.

Signage
Danger from electric current!

DANGER!
Danger to life from electric current!

Touching live parts leads to death.

Damaged insulation or individual parts can be life-threatening. Disconnect the machine from the power supply before any work on the electric system.
Check ¬that no voltage is present! Switch off power supply before maintenance, cleaning and repair operations and secure the machine against being restarted.
If the power supply insulation is damaged, switch off immediately and arrange for repairs.
Never bypass or disable fuses.
Always use fuses with correct amperage when replacing defective fuses.
Keep moisture away from live parts.
Any works on the electrical installations must be carried out by qualified electricians¬.
Annual check of the electric system according to VDE0701.

CAUTION! Risk of cut injuries!
Reaching into moving tools may lead to heavy injuries.

Do not touch rotating diamond blades in any circumstances.
De-energize the machine before replacing the diamond blade.

There are the following symbols and information signs on the machine that refer to potential dangers:

MACHINE DATA

Diamond blades

DANGER!
Risk of injury by defective or incorrectly mounted diamond blades! Wrong rotation direction and damaged diamond blades may cause injuries of personnel! Check diamond blades for broken-off segments and segment pieces, segment foot cracks, diamond blade deformations or signs of wear before starting work. Pay attention to the rotation direction arrows on the diamond blades and guard!

DANGER!
Risk of injury by unchecked or unapproved tool! Diamond blades or buzz saw blades that have not been checked or approved may cause injuries of personnel! Before starting work, check whether a proper diamond blade is mounted. Pay attention to the rotation direction arrows on the diamond blade and guard!

NOTE!
All diamond blades used must be designed in terms of their permissible max. cutting ¬speed¬ to match the max. drive speed and intended application of the machine tool

Type plate
The type plate is located on the base frame of the machine tool.

Installation site requirements

The floor surface must:

Have sufficient load-bearing capacity.
Be slip-proof.
Be level.

Storage requirements

Storage conditions
As a matter of principle, the machine, its components, assemblies or parts must be only stored in the following conditions: do not store outdoors. store in dry and dust-free place. do not expose to aggressive media. protect from solar radiation. avoid mechanical vibrations. storage temperature range 5 to 45°Crelative air humidity, max. 60%. In case of storage for over 3 months, check general condition of all parts andpackaging on a regular basis. If necessary, renew or replace conservation materials.

TRANSPORT

ATTENTION!
Damage through improper transportation! Improper transportation can result in considerable damage of the machine and objects in the vicinity.

Before every transport:

The cutter head must be locked.
The cutter head must be lowered and locked.
The cutting table must be secured by the table lock (for table saw machines).
The machine must be disconnected from power supply.

Due to two transport rollers, the machine can be transported by one or two persons who can use transport handles.

Instruction of using crane lifting eyes
The machine is designed for crane transport by means of the lifting eye. Always check the tighteness of the lifting eyes before using it to transport the machine. To avoid damage, also check that the lifting straps do not touch the motor when lifting.

CAUTION!
Risk of injury due to improper handle when it is transported by crane.

CAUTION!
Risk of injury by standing under the machine when it is transported by crane.

CAUTION!
Risk of injury of falling material from the working table, it is not allowed to have any material on working table when it is transported.

Crane lifting eyes CARACOUP 104 / CARACOUP 100

INSTALLATION

Connection

Before connecting the machine to the power source, make sure that:

Voltage / phase of the power supply, match the date on the type plate of the motor and machine.
The power supply line is grounded according to the safety provisions.
The wire size of the extension cord is sufficient, H07RNF 3×2.5 mm² up to 50m for 230V.

Mounting a diamond blade

To mount a new diamond blade or replace the used one, proceed as follows:

Switch off the machine and interrupt the power supply by pulling the mains cable from the mains outlet.
Loosen the screws on the diamond blade guard so as to be able to remove the front half of the diamond blade guard.
Loosen the nut of the motor shaft and remove the outer cutter flange.
Clean the cutter flange, nut and motor shaft.
Check the parts for signs of wear.
Mount or replace the diamond blade. While doing so, pay attention to the correct rotation direction of the diamond blade and motor shaft.
Replace the outer cutting flange on the motor shaft.
Screw the nut onto the motor shaft again and tighten it firmly.
Replace the front half of the cutting wheel guard to connect it with the rear half.
Tighten firmly the screws on the cutting wheel guard.

NOTE!
The arrow on the cutting wheel indicates correct rotation direction.

NOTE!
The cutting wheel, irrespective of its position or the position of the cutter head, may not touch the table!

Mounting the transport handles and wheels
Mount the transport handles at the appropriate places on the base frame using the supplied washers (4x A8,4 ISO 7089) and the screws (4x M8x30 ISO 4017), the spring washers (4x A8 DIN 127) and the screws (4x M8x20 ISO 4017).

Carat Caracoup 104 Tile Saw Machine Instruction Manual