Fervi 0642 User manual

OPERATION AND
MAINTENANCE MANUAL
Cut-off machine
Art. 0642
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
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PREFACE
Please ensure you have read this manual before any
operation
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
Before undertaking any operation on the machine, it is compulsory to have read this
instruction manual. The guarantee that the machine will function and perform properly is
strictly dependent upon the application of all the instructions contained in this manual.
Operator Qualifications
The workers in charge of using this machine must possess all the necessary information
and instruction and should be given adequate training in relation to safety regarding:
a) Conditions of use for the equipment;
b) Foreseeable abnormal situations, pursuant to Article 73 of Italian Law Decree
81/08 (which adopts the EN rules).
We guarantee the Machine complies with the specifications and technical instructions
described in the Manual on the date of its issuance (shown in this page). On the other
hand, the machine may also be subject to important technical changes in the future,
without the manual being updated.
Therefore, contact FERVI for information about modifications that may have been
implemented.
REV. 3
August 2014
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CONTENTS
1INTRODUCTION ........................................................................................ 5
1.1 Preface..........................................................................................................................6
2GENERAL SAFETY WARNINGS ................................................................... 7
2.1 General safety rules for machine tools ..........................................................................7
2.2 Safety regulations for mitre saws .................................................................................9
2.3 Safety regulations regarding the electric system of machine-tools ............................. 11
2.4 Technical Assistance ...................................................................................................11
2.5 Other provisions .........................................................................................................11
3TECHNICAL SPECIFICATIONS ................................................................. 12
4DESCRIPTION OF THE MACHINE .............................................................. 13
4.1 Main parts of the machine........................................................................................... 14
4.2 Identification plate .....................................................................................................15
5DESCRIPTION OF CONTROLS ................................................................... 16
5.1 Start buttons...............................................................................................................16
6MACHINE SAFETY DEVICES ...................................................................... 18
6.1 Electrical safety devices ..............................................................................................18
6.2 Safety devices against "mechanical" risks ..................................................................18
6.2.1 Protective disc casing ........................................................................................... 18
6.3 Personal Protective Equipment (PPE) .........................................................................19
7MISUSE AND CONTRAINDICATIONS......................................................... 20
8TRANSPORT AND LIFTING ....................................................................... 20
9ASSEMBLY AND COMMISSIONING............................................................ 21
9.1 Unpacking instructions ............................................................................................... 21
9.2 Positioning and fixing on the bench ............................................................................21
9.3 Sparks deflector .......................................................................................................... 22
9.4 Setting the max depth of cut.......................................................................................22
9.5 Connecting the power plug ......................................................................................... 22
10 OPERATION .......................................................................................... 23
10.1 Precautions for use .................................................................................................. 23
10.2 Operating the mitre saw .......................................................................................... 23
10.2.1 Making straight cuts................................................................................................. 24
10.2.2 Making angled cuts .................................................................................................. 25
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11 MAINTENANCE...................................................................................... 26
11.1 Routine maintenance ............................................................................................... 26
11.2 Replacement of the disc ........................................................................................... 27
12 WAREHOUSE STORAGE ......................................................................... 30
13 DISPOSAL OF PARTS AND MATERIALS................................................... 30
14 TROUBLESHOOTING.............................................................................. 31
15 ELECTRICAL CIRCUIT ............................................................................ 31
16 REPLACEMENT PARTS ........................................................................... 32
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1INTRODUCTION
This manual is delivered with the machine, and it must be regarded as an inseparable part of
it.
The manufacturer holds all ownership to material and intellectual property of this manual;
any disclosure or copying, even partial, of this publication without prior written consent is
forbidden.
The purpose of this manual is to convey the necessary knowledge for the use and
maintenance of the Cut-off machine Art. 0642 and to create a sense of responsibility and
knowledge of the capabilities and limits of this machine entrusted to the operator.
As the machine is entrusted to experienced and skilled operators, the following machine must
be perfectly known by the operator if it is to be used safely and effectively.
Operators must be properly trained and prepared; therefore, please make sure this manual is
read and consulted by the staff responsible for commissioning, operating and maintaining the
Cut-off machine. This is to make all operations the safest and most effective possible for
those who carry out these tasks.
Therefore, it is imperative to strictly comply with the requirements in this manual, a
necessary condition for safe and satisfactory operation of the machine.
Prior to installation and use of the Cut-off machine, the authorized personnel shall:
carefully read this technical document;
know which protections and safety devices are available on the machines, their location
and how they work.
It is the responsibility of the buyer to ensure that users are properly trained, that they are
aware of all the information and instructions in this document and that they are aware of the
potential risks that exist while working with the Cut-off machine.
The manufacturer waives any and all responsibility for damage to people and/or
things caused by non-observance of the instructions in this manual.
The Cut-off machine has been designed and built with mechanical guards and safety
devices designed to protect the operator/user from possible injury. It is strictly forbidden to
modify or remove guards, safety devices and caution labels. If you have to do so temporarily
(for example, for cleaning or repair requirements), please make sure that no one can use the
machine.
Modifications to the machine carried out by the user must be considered their sole
responsibility, therefore the manufacturer waives any and all responsibility for any
damage caused to persons and/or property resulting from maintenance performed
by unqualified personnel and in a manner unlike the operating procedures shown
below.
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GRAPHIC REPRESENTATION OF SAFETY,OPERATIONAL AND RISK WARNINGS
The following boxes are designed to attract the attention of the reader / user for the proper
and safe use of the machine:
Pay attention
This highlights behavioural rules to prevent damage to the machine and/or the occurrence of
dangerous situations.
Residual Risks
This highlights the presence of dangers that cause residual risks to which the operator must
pay attention in order to avoid injury or damage to property.
1.1 Preface
For a safe and effective use of the Cut-off machine, you must read this manual carefully to
acquire full knowledge of the machine and the general precautions to be observed during
operation. In other words, machine durability and performance are strictly dependent on how
it is used.
Even if already familiar with the Cut-off machine, it is necessary to follow the instructions
herein, in addition to the general precautions to be observed while working.
Acquire full knowledge of the machine.
Read this manual carefully to understand: operation, safety devices and all necessary
precautions. All this is to allow safe use of the machine.
Wear appropriate clothing for the job.
The operator must wear appropriate clothing, so as to prevent the occurrence of
unpleasant accidents.
Maintain the machine with care.
Using the Machine
The machine must only be used by qualified personnel trained to use the machine by
authorized personnel.
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2GENERAL SAFETY WARNINGS
2.1 General safety rules for machine tools
Risks related to Using the Machine
Do NOT underestimate the risks related to the use of the machine and stay focused on the
work you are carrying out.
Risks related to Using the Machine
Despite the implementation of all safety devices for safe use of the machine, it is necessary to
take note of all the accident prevention requirements highlighted in various parts of this
manual.
Risks related to Using the Machine
Every person who is responsible for the use and maintenance of the machine should first have
read the instruction manual, particularly the chapter dealing with safety.
It is recommended that the plant safety manager get written confirmation of the above.
Risks associated with using the machine
During all work phases with the machine, you should proceed with great caution in
order to avoid damage to persons, to the property or to the machine itself.
Please use the machine only for its expected uses (drilling or tapping).
Don't tamper with the safety devices equipping the machine.
Risks associated with using the machine
Before starting any work on the machine, the operator must wear the appropriate personal
protective equipment (PPE) such as gloves and eye protection (see section 6.6 of this
manual).
1. Always check the efficiency and integrity of the machine.
2. Before connecting the machine to the mains make sure that the switch is in the rest
position.
3. Do not start the machine in an enclosed or poorly ventilated area, or in the presence of
a flammable and/or explosive atmosphere. Do not use the machine in locations which
are damp, wet, or even exposed to the rain.
4. Avoid starting accidentally.
5. Before starting the machine, get used to ensuring that no remaining adjustment or
maintenance wrenches have remained inserted.
6. Keep the workplace tidy and free from hindrances; disorder causes accidents.
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7. Make sure that the work environment is forbidden to children, non-employees and
animals.
8. Do not perform tasks on the machine other than those for which it was designed. Only
use the machine in the manner in which it was intended, as described in this
instruction manual.
9. Work without disturbances.
10.Work areas must be well lit.
11.Always wear eye protection and protective gloves while working. If dust is produced,
use the appropriate masks.
12.Wear appropriate clothing. Loose clothing, dangling jewelry, long hair, etc.., can get
caught in the spindle and in moving parts, causing irreparable injury.
13.Replace worn and/or damaged parts. Before operating, make sure guards and
protections work correctly. If necessary, have them checked by Service staff. Use only
original spare parts.
14.Cut the mains voltage supply to the machine when:
the machine is not being operated;
is left unattended;
you are performing maintenance or adjustment because the machine does not
work properly;
you are replacing its tool;
in case the machine is being moved to another location;
you are cleaning the machine.
15.Do not use the machine in areas with a risk of fire and / or explosion.
16.It is recommended that users of this publication, for maintenance and repair, have a
basic knowledge of mechanical principles and of repair technique procedures.
17.Management in charge of safety is to make sure that the staff responsible for
using the machine has read and understood this manual in its entirety.
18.Management is responsible for safety and verification of the company's risk
status, pursuant to the law.
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2.2 Safety regulations for mitre saws
1. Before use, check that the support surface of the machinery is flat, of suitable strength
and of sufficient ergonomics: for this purpose operate with the aid of a workbench.
2. Secure the workpiece. Use the vice on the machine to keep the workpiece stable.
3. Connect dust extraction equipment. Make sure a vacuum is connected to the machine,
for the suction of dust and chips produced.
4. Before starting work, inspect the piece and remove any foreign material.
5. Do not leave the machine until the disc has completely stopped. For this purpose, only
use the stop controls to stop the machine.
6. Do not slow down or stop the disc with your hands or other objects.
7. Allow the disc to stop on its own!
8. Take proper care of the cutting tools. Cutting tools must be kept intact and clean to
ensure the best possible performance.
9. Never use blades that are less than 2.7 mm thick.
10.Never use the blades for materials other than metal.
11.Wear safety glasses and ear protection. Dust produced during the work can be harmful
to health, combustible or explosive. It is necessary to adopt appropriate protective
measures.
12.Certain kinds of dust are considered carcinogenic. Therefore use a suitable dust suction
device and wear a dust protection mask.
13.Light dust from metals can be flammable or explosive. Always keep the workplace
clean because mixtures of materials can be particularly dangerous.
14.Use the machine only for dry cutting.
15.When there is a danger that the coupled tool may encounter a hidden line or even its
own power cord, hold the power tool using only the isolated handles. Contact with an
electrically live line can electrify the metal parts of the machine and cause an electric
shock.
16.Do not lean against the machine. Serious accidents can be caused if the machine tips
over or if parts of the body come into contact with the cutting wheel.
17.Only use a cutting wheel with a rated speed at least equal to the maximum unloaded
speed of the machine. Before use, check the status of the cutting wheel.
18.Always operate the machine from an side position with respect to the cutting wheel.
19.The cutting wheel must be fitted perfectly and it should be able to turn freely. Perform
a test run for at least 1 minute unloaded.
20.Never use cutting discs that are damaged, ovalised or vibranting.
21.Always properly adjust the stop depth, otherwise the grinding wheel can reach the
surface of the lower part of the base plate.
22.During use, the protective covering of the cutting wheel must be fixed and the hanging
protection guard must function correctly.
23.Do not work with any material containing asbestos or magnesium.
24.Prevent the cutting wheel from undergoing shock, bumps or coming into contact with
grease.
25.During the work of cutting metal a trail of sparks are produced. Install the bracket for
sparks, at the rear of the machine.
26.A cutting wheel block can generate jolting in the machine. In this case, immediately
release the start button
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27.Do not try to force the cutting wheel into the workpiece, or exert too much pressure
while using the machine. In particular, prevent the cutting wheel from becoming
entangled when working on corners, sharp edges etc.. Improper use may damage the
cutting wheel with cracks forming on it.
28.Avoid subjecting the motor to overloads especially when machining large pieces.
During the cutting operation, only exert a small amount of pressure on the handle.
29.Use only cutting wheels with permitted sizes. The diameter of the hole should fit
perfectly with no movement about the tool holder shaft. Never use either reduction
elements or adapters.
30.Never subject the cutting wheel to lateral pressure.
31.The cutting wheel gets very hot during operation, do not ever touch it with your hands
before it is completely cool.
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2.3 Safety regulations regarding the electric system of machine-
tools
Risks associated with using the machine
1. Do not modify the electrical system in any way. Any attempt in this regard may
jeopardize the operation of electrical devices, causing malfunction or accident.
2. Work carried out in the electrical system of the machine must, therefore, be carried out
only by qualified and authorized personnel.
3. If you hear unusual noises, or you feel something strange, immediately stop the
machine. Then carry out an inspection and, if necessary, perform any repairs as
required.
1. The supply voltage must correspond to that stated on the identification plate and in the
technical specifications. Namely: 230 Vac / 50 Hz.
Never use any other type of power supply!
2. The use of a circuit breaker on the electric power supply is recommended. For more
detailed information, contact a trusted electrician.
3. The power socket must be equipped with a grounding lead. The size of any extension
cables must be equal to or greater than the one of the machine's own power supply
cable (diameter 1.5 mm2).
4. The power supply cable (and its possible extension cable) should never come in contact
with hot objects, sharp edges, wet or oiled surfaces.
5. The power supply cable (and its possible extension cable) should be checked
periodically, and before each use, for making sure they have no signs of damage or
wear. If these are not in good condition, do not use the machine and replace the
damaged cable.
6. Do not use the power cord to detach its plug from the socket.
2.4 Technical Assistance
For any problems or concerns, please contact, without hesitation the Customer Service
Department of your dealer, who has competent and specialized staff, specific equipment and
spare parts.
2.5 Other provisions
IT IS FORBIDDEN TO TAMPER WITH SAFETY DEVICES
The first thing to do when starting work is to check for the presence and integrity of the
protections and the operation of the safety devices.
If any defect is detected, do not use the machine.
Even more so, it is strictly forbidden to modify or remove guards, safety devices,
labels and indication signs.
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3TECHNICAL SPECIFICATIONS
Model
Art. 0642
Rated voltage (V)
230
Power (W)
2000
Frequency (Hz)
50
Disc dimensions (mm)
355 x 3.0 x 25.4
Disc speed (r/min)
3800
Cutting rotation angle
± 45°
Cutting capacity square (mm)
100 x 100
Cutting capacity rectangular (mm)
200 x 40
Cutting capacity round (mm)
Ø 100
Weight (kg)
20
Acoustic pressure level (dB(A)) as specified in UNI
EN ISO 3744:2010
91.0 ± 3.2
Acoustic pressure level (dB(A)) at the operator
position as specified in UNI EN ISO 11202:2010
95.6 ± 4.0
Hand-arm transmitted vibration ahv (m/s2)
6.230 ± 0.710
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4DESCRIPTION OF THE MACHINE
The Cut-off machine (Art. 0642) is only used for the dry cutting of metals, within the limits
recommended by the Manufacturer and the safety and health norms.
Other types of use, or the extension of use beyond that envisaged, does not
correspond to the designation attributed by the manufacturer, and therefore the
latter cannot accept any responsibility for any damage resulting therefrom.
Improper machine operation
The machine was designed and manufactured for a specific use, different uses and non-
compliance with technical parameters established by the Manufacturer may be
hazardous to the operator.
In particular, it is absolutely forbidden to cut non-metal materials.
The Cut-off machine (Art. 0642) can perform only vertical cuts, the workpiece can be tilted
by up to 45°.
It mainly consists of the following parts:
the fixed pedestal, with clamp for locking the workpiece;
the electric motor and the circular blade (disc) mounted on the cutting unit of the
machine;
the handle for manual operation.
The motor rotates at a constant speed.
The mitre saw must be installed and used on flat supporting surfaces, with adequate
ergonomic and resistance features, such as a workbench or a pedestal.
The mitre saw can only operate in indoor workplaces (production halls, warehouses,
woodworking areas, etc.) and in any case away from moisture and the weather.
The operating temperature range is –5 / + +50°C.
The environment must also be sufficiently illuminated so as to ensure operation in maximum
safety (at least 200 lux is recommended).
Improper machine operation
Do NOT use the machine in areas with are humid, wet and exposed to rain, snow or
hail.
Do NOT use the machine in areas with a high risk of fire and/or explosion !
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4.1 Main parts of the machine
Figure 1 - Main parts of the machine
1
Confirmation button
6
Fixed disc guard
2
Start button
7
Movable disc guard
3
Handle
8
Clamp jaws
4
Electric motor
9
Vice adjustment handle
5
Pedestal
10
Locking pin
1
2
3
4
5
6
7
8
9
10
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4.2 Identification plate
The identification plate shown below is attached to the machine:
Figure 2 –Identification plate
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5DESCRIPTION OF CONTROLS
5.1 Start buttons
The buttons for starting the mitre saw, or activating the disc are positioned on the control
handle. These buttons are (Figure 3):
a confirmation button located on the side of the handle (ref. 1);
a sustained action switch located under the handle (ref. 2).
This system is based on a double-start command (switch + confirmation button) protects the
operator against accidental operation, for example in the case of impacts against the start
command.
Figure 3 –Start buttons.
1
Confirmation button
2
Start button
2
1
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To perform the cutting operation it is necessary to press (and hold down) both start buttons,
as shown in Figure 4 i.e.:
press the confirmation button (1) with the thumb of the right hand;
press the start switch (2) with the index finger of the right hand.
Figure 4 –Operating the switches.
Cutting hazard
It is absolutely forbidden to by-pass the safety feature constituted by the double start
command by locking the button in the "ON" position.
NOTE: Given the operator's workstation and the reduced overall size of the
machine, the sustained action start button is also an emergency stop switch.
Emergency
In emergency situations, immediately release the start button (12) and the handle and move
away from the machine.
Also during normal operation, to stop the rotation of the blade, release the starter switch (2).
It automatically returns to the up position ("OFF").
Cutting hazard
After releasing the start switch (2), the blade continues to rotate by inertia.
Do not put body parts like hands and/or fingers near the moving blade!
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6MACHINE SAFETY DEVICES
6.1 Electrical safety devices
In the event of malfunction or breakdown, the Cut-off machine is equipped with a power
cable and plug without grounding conductor, as it is equipped with double isolation.
The plug must be plugged into an appropriate outlet, the metal frame of the machine non-
grounded. Extension cables must be of a section equal to or greater than the power cable of
the machine.
Electric Shock
Improper connection of the machine’s grounding conductor can result in the risk of electric
shock. Do not make any modifications to the electrical system.
Check with a qualified electrician if you don't understand the grounding
instructions.
6.2 Safety devices against "mechanical" risks
6.2.1 Protective disc casing
The safety guards on the cutting disc are constituted by fixed casing and movable casing, as
shown in Figure 5.
They have the task of preventing parts of the operator's body, particularly hands and/or
fingers, from coming into direct contact with the disc.
Furthermore, this prevents the splinters, dust or blade fragments that eventually get
separated from being thrown towards the operator's face.
The movable casing on the disc is articulated to the saw body and it opens progressively as
the blade is lowered to allow the cutting of the workpiece.
Conversely, the blade is completely protected when it is in the resting position, i.e. when fully
raised.
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Figure 5 –Protective disc casing.
In this configuration, the upper part of the blade is not used, and is protected by the upper
casing that is locked in the closed position and is integral to the handle.
6.3 Personal Protective Equipment (PPE)
Use of PPE
ALWAYS use appropriate personal protective equipment (PPE, see Figure 9) such as:
Gloves;
Goggles or face shields;
Overalls or aprons;
Safety shoes;
Ear protection devices (ear muffs, ear plugs, etc.)
Figure 6 –Personal Protective Equipment.
Disc partially
uncovered
Fixed casing on the
sides and behind the
blade
Movable casing under
the disc (cutting
area)
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7MISUSE AND CONTRAINDICATIONS
The following actions described, which obviously cannot cover the entire range of potential
possibilities of "misuse" of the machine, are to be considered strictly prohibited.
IT IS STRICTLY FORBIDDEN !!
To hold the piece to be cut with your hand;
Using the machine without efficient safety guards;
Using the machine for purposes other than those for which it is designed, in particular,
for cutting materials other than metal;
To exceed the cutting capacity stated by the manufacturer;
Using the machine without connecting dust/chip vacuum extraction equipment;
Trying to stop the blade with a piece of wood or another object;
Using cutting discs of a thickness of less than 2.7 mm or with adapters for the central
hole;
To leave the machine unattended with the plug inserted.
To allow untrained staff to use the machine;
To operate this machine if you are not psychophysically fit;
To use the machine without due attention;
To use the machine without using suitable personal protective equipment, such as
safety shoes and gloves, goggles or face shields, ear protection, etc.;
Using the machine outdoors and in adverse weather conditions;
To use the machine in potentially explosive atmospheres;
To use the machine in inadequate light;
To let the machine come into contact with foodstuffs;
To tamper with equipment and/or safety devices;
To lubricate the blade before, during and after processing.
8TRANSPORT AND LIFTING
The weight of the Cut-off machine (ART.0642) is 20 kg, so it can be lifted and moved by
hand by a single operator. To do so, follow the instructions below:
disconnect the power plug from the outlet and collect the cord;
hold the machine under the pedestal, with both hands;
lift the machine and move it to the desired point.
Machine transport
All transport operations must ALWAYS be carried out when the machine is stopped and
no pieces of wood are on the machine table.
ALWAYS disconnect the power plug.
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