Cardi PE 400 User manual

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SAFETY AND USER MANUAL FOR:
WALL SAW PE 400.
USA - CANADA
CARDI s.r.l.
via Leonardo da Vinci, 21 I-24030 Pontida (BG), Italy
tel. [phone] fax. [phone]
[email protected] www.cardi.biz

1
2
3
B
C
A
H
E

45
6
P
N
O
I
II

SERIAL #
NO LASER
LASER
OK OK
7
8
9

10
10/A
10/C
10/E 10/F
10/D
10/B

11
11/A
11/C
11/E
11/G
11/F
11/H
11/D
11/B

12
I

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1
Your CARDI hand-held wall saw is a power tool designed to make straight cuts in stone-
like materials like reinforced concrete, bricks, masonry, natural stone, using laser-welded
diamond blades only.
arning: Do NOT use circular saw blades or other kinds of blades not laser-
welded. Failure to follow this warning may result in serious personal injury. See
figure 8 and 9.
General safety Rules
General safety Rules
WARNING! Read all instructions. Failure to follow all
instructions listed below may result in electric shock, fire
and/or serious injury. The term "power tool" in all of the
warnings listed below refers to your mains operated
(corded power tool or battery operated (cordless
powertool.
SAVE THESE INSTRUCTIONS
1) Work area
a) Keep working area clean an well lit. Cluttered
and dark areas invite accidents.
b) Do not operate power tools in explosive
atmospheres, such as in the presence
of flammable liqui s, gases or ust.
Power tools create sparks which may ignite
the dust or fumes.
c) Keep chil ren an bystan ers away
while operating a power tool.
Distractions can cause you to lose control.
2 Electrical safety
a) Power tool plugs must match the outlet. Never
mo ify the plug in any way. Do not use any
a apter plugs with earthe (groun e ) power
tools. Unmodified plugs and matching outlets will
reduce risk of electric shock.
b) Avoi bo y contact with earthe or
groun e surfaces such as pipes,
ra iators, ranges an refrigerators.
There is an increased risk of electric shock
if your body is earthed or grounded.
c) Do not expose power tools to rain or
wet con itions. Water entering a power
tool will increase the risk of electric shock.
) Do not abuse the cor . Never use the
cor for carrying, pulling or unplugging
the power tool. Keep cor away from
heat, oil, sharp e ges or moving parts.
Damaged or entangled cords increase the
risk of electric shock.
e) When operating a power tool out oors,
use an extension cor suitable for
out oor use. Use of a cord suitable for
outdoor use reduces the risk of electric
shock.
3 Personal safety
a) Stay alert, watch what you are oing an use
common sense when operating a power tool.
Do not use a power tool while you are tire or
un er the influence of rugs, alcohol or
me ication. A moment of inattention while
operating power tools may result in serious
personal injury.
b) Use safety equipments: always wear
eye protection. Safety equipment such as
dust mask, non-skid safety shoes, hard
hat, or hearing protection used for
appropriate conditions will reduce personal
injuries.
c) Avoi acci ental starting. Ensure the
switch is in the off position before
plugging in. Carrying power tools with
your finger on the switch or plugging in
power tools that have the switch on invites
accidents.
) Remove any a justing key or wrench
before turning the power tool on. A
wrench or a key left attached to a rotating
part of the power tool may result in
personal injury.
e) Do not overreach. Keep proper footing
an balance at all times. This enables
better control of the power tool in
unexpected situations.
f) Dress properly. Do not wear loose
clothing or jewellery. Keep your hair,
clothing an gloves away from moving
parts. Loose clothes, jewellery and long
hair can be caught in moving parts.
g) If evices are provi e for the
connection of ust extraction an
collection facilities, ensure these are
connecte an properly use . Use of
these devices can reduce dust related
hazards.
h) Use auxiliary han les supplie with the
tool. Loss of control can cause personal
injury.
4 Power tool use an care
a) Do not force the power tool. Use the
correct power tool for your application.
The correct power tool will do the job better
and safer at the rate for which it was
designed.
b) Do not use the power tool if the switch
oes not turn it on an off. Any power
tool that cannot be controlled with the
switch is dangerous and must be repaired.
c) Disconnect the plug from the power
source before making any a justments,
changing accessories, or storing power
tools. Such preventive safety measures
reduce the risk of starting the power tool
accidentally.
) Store i le power tools out of the reach
of chil ren an o not allow persons
unfamiliar with the power tool or these
instructions to operate the power tool.
Power tools are dangerous in the hands of
untrained users.
e) Maintain power tools. Check for
misalignment or bin ing of moving
parts, breakage of parts an any other
con ition that may affect the power
tools operation. lf damaged, have the
power tool repaired before use. Many
accidents are caused by poorly maintained
power tools.

2
f) Keep cutting tools sharp an clean.
Properly maintained cutting tools with
sharp cutting edges are less likely to bind
and are easier to control.
g) Use the power tool, accessories an
tool bits etc., in accor ance with these
instructions an in the manner inten e
for the particular type of power tool,
taking into account the working
con itions an the work to be
performe . Use of the power tool for
operations different from intended could
result in a hazardous situation.
5 Service
a) Have your power tool service by a qualifie
repair person using only i entical replacement
parts. This will ensure that the safety of the power
tool is maintained.
Additional safety rules for wall saws
Always
wear safety
goggles
Always
wear
safety
gloves
Always wear
ear
protection
Always
wear safety
shoes
Always
wear dust
mask
Instructions before use
Instructions before use
In the following text, figures are identified by numbers,
details inside the figures by letters. Figures are depicted on
the first pages of this user manual.
Power supply
Earth
since your wall saw operates with water, its metallic
parts are connected to the earth;
make sure that the socket and possible extension
cords and multiple sockets have the earth
connection and that your electrical system is
properly connected to the earth.
arning: for your safety, it is important that
the whole system (electrical system, extension
cords, sockets etc.) is connected to the earth.
If you are not sure, ask a ualified electrician
for a check.
Extension cords
when you have to operate with your wall saw far
from an electrical socket, you can use an extension
cord. If you use it, make sure that the section of the
cord is suitable and that the cord is provided with
ground conductor;
the extension cord (made up of cable, plug and
socket) must be suitable for outdoor use. It is better
if the cord is made of rubber and it is H07RN-F;
follow the chart shown in figure 13 on this manual
for the choice of the right section of the conductors;
if you use more than one extension cord make sure
that every cable in each extension cord has a
section not lower than the value shown on the chart
in figure 13;
remember that the more an extension cord is long
the more the voltage drop is high and the worse is
the operation of your wall saw. Do not use
extension cords if you have to operate too far from
the electrical socket.
Preliminary operations
In order to prepare your wall saw to operate, follow these
steps. Before proceeding with preparation make sure that
the plug is disconnected from the power supply.
a) b) fix the main handle (A) in the more comfortable
position for the application as shown in figure 4.
arning: not using handles can result in loss of
control of your wall saw and serious personal
injury.
b) connect the uick hose connector (C) to a proper
water supply;
PRCD: portable residual current device
your wall saw is e uipped with a safety portable
residual current device (PRCD) assembled on the
cord. This device is shown in figure 5;
never use the wall saw without PRCD;
before starting to cut, make sure the PRCD works
properly. In order to do so, plug the wall saw in and
press the button Reset (O): a red led will light up
(P) showing that electricity is available toward the
wall saw. Than press the button Test (N) that tests
if the device works properly. When you press it the
circuit breaker inside the PRCD should cut the
power off leading the switch automatically to go to
the off position and the red led to go off;
if, when cutting, the PRCD cuts the power: stop
working, set the switch on OFF position and bring
your chain saw to an authorized service centre in
order to remove the causes of the electrical
dissipation.
ON/OFF switch
See figure 6 in order to understand how to use the switch
(figure 2 E).
Your switch is e uipped with a safety lock-off device. This
device ignite the motor only if you follow first step I and than
step II, as shown in figure 6. This prevents the wall saw from
accidentally self-starting.
Connection to a water supply
Wet cutting reduces risks connected with dust spreading.
We recommend to use your wall saw with water. If you want
to cut without water wear a proper dust mask to protect
yourself from dust. In wet cutting:
check at regular intervals that none of the water
system components are damaged. Check in
particular the valve, the uick hose connector and
the pipe;
use only the water pipe provided with your wall
saw. The water pipe includes also a valve and a
quick hose connector;
the maximum pressure of incoming water must be 4
bar;
use just clean water;
prevent water from entering the motor or other
electrical components.

3
Checks and precautions to avoid
structural damages and damages to the
plant
Before starting any cutting activity, talk with the construction
manager or the planner in order to make sure that the cut
doesn’t:
make any damage to the structure of the building
and doesn’t change the structural characteristics of
the construction;
damage any water or gas pipeline or any electric
mains.
Blade choice
Your Cardi wall saw has been designed to cut building
materials such as concrete, reinforced concrete, bricks,
masonry, natural stones, tiles etc, using laser welded
diamond blades (figure 9).
arning: Do NOT use circular saw blades or
other kind of blades not laser-welded. Failure to
follow this warning may result in serious personal
injury. See figure 8 and 9.
Ask your dealer about the best blade for your application.
The blade must have:
maximum diameter: 400 mm;
hole diameter 30 mm or 25,4 mm. Check the correct
diameter of the hole accordingly to the specification
on the “Technical Data Sheet” supplied together
with the machine;
thickness between 2 and 3 mm;
maximum rotating speed, given by the blade
manufacturer, higher than the maximum rotating
speed of the wall saw, shown on the data plate (see
figure 12 I).
Use blades with diameter, hole dimension and rotating
speed compatible with your specific wall saw model. Use of
blades with inappropriate dimensions can result in
misalignment, vibrations, irregular rotation and loss of
control causing serious injury.
Check the blade before use. Do not use damaged blades.
Blade mounting and replacement
Before mounting or replacing the blade (figure 1 H) make
sure the wall saw is disconnected form the electric supply.
For blade mounting or replacement, follow these directions,
referring to figure 10:
unscrew the blade-tightening screw (10/A), using
the tubular spanner provided with your wall saw;
remove the blade-tightening screw and the flange
(10/B);
insert the new blade or replace the old one (10/C);
insert the flange (10/D);
insert the blade-tightening screw (10/E)
tight the blade-tightening screw (10/F);
Mounting and replacement of the
FLUSH CUT BLADE
Before mounting or replacing the blade (figure 1 H) make
sure the wall saw is disconnected form the electric supply.
For blade mounting or replacement, follow these directions,
referring to figure 11:
unscrew the blade-tightening screw (11/A), using
the tubular spanner provided with your wall saw;
remove the blade-tightening screw and the flange
(11/B);
insert the flange for flush cut blade (11/C);
insert the flange tightening screw (11/D);
tight the flange tightening screw (11/E);
insert the new blade or replace the old one (11/F);
insert the blade-tightening screws (11/G);
tight the blade-tightening screws (10/H);
Fixing the material to be cut and
dimensional limits of the material to be
cut
if the material you are cutting is a block not part of a
construction, fix the block in order to prevent its
movement;
prevent the block from shifting or tearing the
anchorages when you are cutting.
Environmental conditions
do not expose the wall saw to rain, ice or snow;
prevent water or any other li uid from coming into
contact with the electric parts of your machine;
do not use the wall saw in explosive atmospheres,
for instance inflammable li uids, gas or dust. The
electric wall saw produces sparks which can ignite
dust or smoke.
Overhead cutting (ceiling cutting)
arning: your wall saw is NOT intended to
perform overhead cutting (upward).
Operating Instructions
Operating Instructions
After having followed the instructions given in the previous
Preliminary operations paragraph, follow these directions in
order to perform the cut.
arning: do not touch any moving parts of
your wall saw, in particular the blade, when
operating.
switch your wall saw on and move closer to the
material to be cut. When the blade touches the
material push till you reach the desired cutting
depth;
your wall saw is intended to perform just straight
cuts;
avoid friction between the blade-side and the
material: move the wall saw just forward avoiding
side movement of the blade. The friction can
overload the motor;
arning: when cutting, the blade can bind in
the cut causing the saw to kickback. In this
case the saw tends to move toward or away
from the operator. The kickback is dangerous
for the operator and it can cause serious injury.
use the handles and hold your wall saw firmly with
both hands and be ready to resist to a possible
kickback;
cutting materials containing wood, cork, rubber,
foam polystyrene can result in problems moving
forward the machine. If you have this kind of
problems, stop cutting and remove all materials

4
listed before and proceed with cutting operations. If
you cannot remove these materials, stop cutting
and cut in another position;
in case the electric power goes off, trigger off the
switch to prevent the machine from accidentally self
starting;
when you complete the cut, trigger the switch off
and wait till the blade comes to a complete stop.
Then pull the wall saw out of the cut and close the
water valve. Watch out! The blade and the cutting
area can be very hot ad cause severe burns.
Electronic devices
Your wall saw is e uipped with a CARDI multifunction
electronic device that includes a soft-start and an electronic
clutch:
the soft-start allows the motor soft-start, reduces
current peak that occurs when you switch the motor
on, helps you when you begin cutting, allowing
gradual blade rotation and avoiding jerks at the
operator’s arm, and allows you to use your wall saw
connected to the household electric system
e uipped with high sensitivity automatic switch;
the electronic clutch ensures that the current
absorbed by your wall saw, proportional to the
motor load, is below the safety upper limit. In case
the current absorbed exceeds the limit, it cuts off
power toward the motor, preventing damages.
When the overload is over, the device gives back
power to the motor that begins working again;
if the electronic clutch operates fre uently means
that the wall saw is not used properly. Possible
causes can be a not suitable forward speed, an
excessive friction between the blade-side and the
material, excessive cutting depth. In these cases,
stop cutting and let the machine turn with no load
for some seconds, helping the motor cool down.
Maintenance - Service - arranty
Maintenance - Service - arranty
Periodic maintenance
at the end of the work, after having removed the
blade, blow compressed air inside the rotating
motor in order to remove dust and powder. Do this
operation wearing protective goggles;
before starting any other cleaning, maintenance or
lubrication operation make sure that the wall saw is
unplugged;
keep your wall saw clean and dry, in particular its
handles and its moving parts;
never use solvents or other harsh chemicals for
cleaning your wall saw;
after use put your wall saw in a dry, safe and
inaccessible to children place;
we recommend to lubricate hinges, joints and pivots
belonging to cutting-depth setting system with a
suitable water-repellent spray
gears are lubricated by lubricating oil and grease
which are suited for any external temperature. You
don’t have to check the oil level or to fill it up.
always unplug the wall saw during check or blade
replacement;
never unplug the wall saw pulling the cord;
inspect often the feeding cable and extension
cords, making sure that they don’t have any
damage like cuts, abrasions or live conductors. If
you find a damage, ask to a CARDI authorized
service centre for replacement;
do not use the wall saw with damaged components
or with malfunctions, in particular when the switch
doesn’t work properly. In these cases, ask a CARDI
authorized service centre for replacement.
Service
after 250 hours worked, bring your wall saw to a
CARDI authorized service centre for periodical
check;
any repairing on your wall saw must be carried out
by CARDI authorized service personnel only. Ask
your dealer for the list of the CARDI authorized
service centres;
your machine's serial number is stamped on the
machine or printed on the data plate as shown in
figure 7;
Use original CARDI spare parts only.
arranty
Your product is under CARDI warranty for 12 months,
starting from the date of purchase. This warranty is against
faulty workmanship, flaws material and design problems.
The warranty covers free components replacement,
manpower needed for replacement and wearing materials
such as oil and lubricants if intact before the repairing
operation. The warranty doesn't cover the replacement of:
components of the product replaced or modified by
people not authorized by CARDI;
components damaged by carelessness, not
suitable use or overloaded;
components of products from which safety devices
have been removed;
worn wearing parts replaced during repair.
This warranty does not apply to products that have been
damaged by carelessness like water entering the wall saw,
lack of periodic cleaning and maintenance, damage of the
threaded components or the spindle etc.
The life of wearing parts is variable depending on using time
and the kind of job they are used for. Examples of wearing
parts are: cables, switches and plugs, brushes,
commutators, clutch plates, ball and roller bearing not in oil,
sealing rings, transmission spindles, filters, etc.
If during repairing under warranty, a wearing part is worn
and this can affect the safety and the operation of your
product, the customer is asked to pay for the replacement of
these components not under warranty. If the customer
refuses this, no repairing operation will be carried out.
The warranty covers free replacement of components which
are defective due to wrong manufacturing or assembly, if the
product is brought to an authorized service centre and if:
the product is together with a purchasing document
stating when the product has been purchased.
Valid purchasing documents are invoices or
delivery certificates;
maintenance operations have been carried out
every 250 working hours, replacing the worn
wearing parts;
no unauthorized people have operated on the
product;
the product has not been misused and it has been
used accordingly with the directions given in this
user manual;
all safety directions have been followed.
Your CARDI product is not under warranty if:

5
the product has been serviced by people not
authorized by CARDI.
damages are due to incorrect use and/or
carelessness. Dents due to drops or strokes will be
considered evidence of carelessness;
damages have been caused by mechanical or
electrical overload;
damages have been caused by water, mud or any
other li uid entering the product.
When your product is under warranty, in some cases, like if
the CARDI authorized service personnel think the repairing
is too expensive to be carried out, the free substitution of the
product is possible. In addition, the substitution under
warranty is provided after two fruitless reparation attempts
and after the authorization of a CARDI service manager. In
case of substitution, the customer is, usually, re uested to
pay for the worn wearing parts of the replaced product.
User-replaceable components
No components of your CARDI product can be replaced by
the user. Replacement must be carried out by CARDI
authorized personnel only.
CARDI service centres - Address list:
Ask your dealer for a CARDI service centres address list.
Package Contents
Package Contents
For the list of contents refer to the Spare Parts List, specific
for your model, located in the package together with this
manual.
Products to the end of their life.
The symbol on the left, that you can find on the product or on its packaging indicates that this product may not be treated as
household waste. At the end of its life the products must be handed over to the applicable collection point for the recycling of
electrical and electronic equipment.
Be sure that this product is disposed correctly. You will help prevent potential negative consequences for the environment and
human health. For more detailed information about what to do when your product doesn't work and is not fixable, contact the dealer
where you did purchase the product.
Your product has been introduced new on the market after August 13th 2005.
This manual is subject to modifications without notice.
A RN IN G:
THE MAN UFACT URER DEC LINES ALL RESPONSABILITY
IN C ASE OF NO RESPEC T OF TH E AB OVE RITTEN
"SA FET Y AN D OPERATING INSTR UCTIONS" .

CAR ID

www.cardi.biz

www.cardi.biz
CARDI s.r.l.
via Leonardo da Vinci, 21 I-24030 Pontida (BG), Italy
tel. [phone] fax. [phone]
[email protected] www.cardi.biz