Barranca Diamond CAB COMBO User Manual

CAB COMBO WORKSHOP

OWNER’S MANUAL AND OPERATING INSTRUCTIONS

Revision 104	04.2013

Manual Part# 164271

Caution: Read all safety and operating instructions before using this equipment. This manual MUST accompany the equipment at all times.

Barranca Diamond Products, Inc. 1315 Storm Parkway

Torrance, CA 90501 Toll-Free: [phone] Phone: [phone] Fax: [phone] www.barrancadiamond.com

TABLE OF CONTENTS

Thank you for selecting the Barranca Diamond Cab Combo Workshop. We are certain that you will be pleased with your purchase. Barranca Diamond takes pride in producing top quality products for hobbyists and commercial lapidary users throughout the world. This product is manufactured in the United States.

This owner’s manual contains information necessary to operate and maintain your Cab Combo Workshop safely and correctly. Operated correctly, the Cab Combo Workshop should provide you with years of service. Please take the time to familiarize yourself with the Cab Combo Workshop by reading and reviewing this manual.

If you should have questions concerning your Cab Combo Workshop, please call Barranca Diamond at: [phone] or Toll Free: [phone].

TABLE OF CONTENTS

SAFETY
Safety Precautions	3
California Proposition 65 Warning	6
Electrical Requirements	7
PRODUCT SPECIFICATIONS	9
SETUP
Contents	10
Unpacking	10
Transport	10
Installation of Blade	11-12
Rock Vise	13
OPERATION AND ADJUSTMENT
Pre-Start	14
Start-Up	15
Pump Set-Up	16-17
Needle Valves	17
Drain Valves	17
Trim Sawing	18
Diamond Wheels	18-19
Expandable Drum & Resin Belts	20
Polishing with Diamond Paste	20
Polishing with Leather Buff Pad	21
MAINTENANCE

Diamond Wheel Replacement	22
Coolant Replacement	27
Belt	27
Blade Arbor & Pulleys	28
Electric Motor	28
Diamond Blade	29
Submersible Pump	30

EXPLODED VIEW & PARTS LIST 32-36

WARRANTY

37-39

2

CAB COMBO WORKSHOP

SAFETY

SAFETY PRECAUTIONS

Read and follow all safety, operating and maintenance instructions. Failure to read and follow these instructions could result in injury or death to you or others. Failure to read and follow these instructions could also result in damage and/or reduced equipment life. In order to prevent injury, the following safety precautions should be followed at all times!

READ OWNER'S MANUAL BEFORE USE

Before using this equipment, ensure that the person operating this machine has read and understands all of the instructions in the manual. Precaution is the best insurance against accidents. Read and understand all safety precautions, messages, warnings and hazard symbols. You are responsible for your own safety.

ALWAYS USE SAFETY GLASSES

Safety glasses should always be worn when working around power tools. In addition, a face, dust mask or respirator should be worn if a cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses and may not prevent eye injury - they are NOT safety glasses.

USE PROPER APPAREL

Do not wear loose clothing, gloves, neckties, rings, bracelets or other jewelry that may be caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair. Hand protection (plastic gloves) and a shop bib are recommended during sawing to prevent stains to clothing. Avoid prolonged exposure of skin to the sawing lubricant and wash skin immediately after contact. Do not touch the work material until the motor is off and the machine has come to a complete stop.

ALWAYS USE HEARING PROTECTION

To reduce the possibility of hearing loss, always use hearing protection when operating power equipment.

KEEP GUARDS IN PLACE

In order to prevent injury, never operate the saw without the guards in place!

REMOVE ADJUSTING KEYS AND WRENCHES

Form a habit of checking to see that keys and adjusting wrenches are removed from the power tool before

it is turned on.

ELECTRICAL SHOCK

Never touch electrical wires or motor components while the motor is running. Exposed, frayed or worn electrical wiring and plugs can be sources of electrical shock that could cause severe injury or burns. Use the GFCI (Ground Fault Circuit Interrupter Switch) included with the unit attached to the main motor power cord plug and keep plugged into the power receptacle outlet source.

3

CAB COMBO WORKSHOP

SAFETY

DISCONNECT TOOLS

Power tools should always be disconnected before servicing or when changing accessories, such as blades, bits, cutters and the like.

REDUCE THE RISK OF UNINTENTIONAL STARTS

Make sure the ON/OFF switch is in the OFF position before plugging in a power tool.

ROTATING OR MOVING PARTS

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds or guards removed.

MAINTAIN TOOLS WITH CARE

Keep tools clean for the best and safest performance. Always follow maintenance instructions for lubricating and when changing accessories.

KEEP WORK AREA CLEAN

Cluttered work areas and benches invite accidents.

DO NOT USE IN DANGEROUS OR HAZARDOUS ENVIRONMENTS

Do not operate equipment in dangerous or hazardous environments. Do not use power tools in damp or wet locations nor expose them to rain. Always keep the work area well lighted. Always work in a well ventilated area.

KEEP CHILDREN AWAY

All visitors and children should be kept a safe distance from the work area. Keep power cords disconnected when tool is not in use.

MAKE THE WORKSHOP KID-PROOF

Make the workshops kid-proof by using padlocks, master switches and by disconnecting all power cords.

USE THE RIGHT TOOL

Do not force a tool or an attachment to do a job that it was not designed to do.

SECURE WORK

Clamps or a vise should be used to hold work whenever practical. Keeping your hands free to operate a power tool is safer.

DO NOT FORCE THE TOOL

A power tool will do a better job and operate more safely at the feed rate for which it was designed.

USE THE RIGHT TOOL TO SERVICE THE SAW

Do not force a tool or an attachment when servicing or operating the Cab Combo Workshop. Use the correct tools for service or adjustments.

4

CAB COMBO WORKSHOP

SAFETY

DO NOT OVERREACH

Keep proper footing and balance at all times by not overreaching.

DO NOT OPERATE A TOOL WHEN TIRED

When tired, take a break and relax.

DIRECTION OF FEED

Always feed work into a blade or cutter in the direction shown in this manual. All blades, grinding wheels or polishing belts should always be installed such that rotation is in the direction of the arrow imprinted on the blade, wheel or belt.

ONLY OPERATE AT THE PROPER SPEED

Severe personal injury and damage to the motor or equipment can result if operated at speeds above maximum.

NEVER LEAVE A TOOL RUNNING UNATTENDED – TURN POWER OFF

Do not leave a tool until it comes to a complete stop. Always turn the tool off, and disconnect the power cord to its source, when leaving the work area or when work is finished. Do not leave extension cords attached to the power cord or power receptacle (wall outlet) when leaving the work area.

CHECK FOR DAMAGED OR WORN PARTS

Before using a power tool, check for damaged parts. A guard or any other part that is damaged should be carefully checked to determine if it would operate properly and perform its intended function. Always check moving parts for proper alignment or binding. Check for broken parts and mountings and all other conditions that may affect the operation of the power tool. A guard, or any damaged part, should be properly repaired or replaced.

USE RECOMMENDED ACCESSORIES AND PARTS

Consult the owner’s manual for recommended accessories and parts. Using improper parts and accessories may increase the risk of personal and/or bystander injury.

USE THE PROPER EXTENSION CORD

If using an extension cord, make sure it is in good condition first. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage that will result in a loss of power and overheating. Table on page 8

shows the correct AWG (American Wire Gauge) size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

USE A GROUND FAULT CIRCUIT INTERRUPTER

Use of a Ground Fault Circuit Interrupter (GFCI) between the end of power cord and wall outlet is required at all times.

USE THE PROPER POWER SOURCE

This tool is only to be used with a 120 volt 60 HZ power source. Ensure power source is at least 15 amps and 110 to 120 volts. Low voltage current can adversely effect electric motor performance and

overall life.

5

CAB COMBO WORKSHOP	SAFETY

USE THE RECOMMENDED COOLING AND LUBRICATING FLUIDS

Never operate a tool dry that requires coolant or lubricant. This can lead to shortened tool life, tool damage and personal injury.

MAINTAIN TOOLS WITH CARE

Keep the diamond blade sharp, the sawing lubricant clean and reservoir filled to the correct level for the best and safest performance. Always follow the maintenance instructions for sharpening the blade, lubricating and servicing the Cab Combo Workshop.

SILICA DUST WARNING

Grinding/cutting/drilling of masonry, concrete, metal and other materials with silica in their composition may give off dust or mists containing crystalline silica. Silica is a basic component of sand, quartz, brick clay, granite and numerous other minerals and rocks. Repeated and/or substantial inhalation of airborne crystalline silica can cause serious or fatal respiratory diseases, including silicosis. In addition, California and some other authorities have listed respirable crystalline silica as a substance known to cause cancer. When cutting such materials, always follow respiratory precautions.

Use appropriate NIOSH-approved respiratory protection where dust hazard may occur. Paper masks or surgical masks without a NIOSH approval number are not recommended because they do little to protect the worker. For more information about respirator programs, including what respirators have

received NIOSH approval as safe and effective, please visit the NIOSH website at: http://www.cdc.gov/niosh/topics/respirators

Observe OSHA regulations for respirator use (29 C.F.R.§1910.134 and §1503.1). Visit http://www.osha.gov for more information.

CALIFORNIA PROPOSITION 65 MESSAGE

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contain chemicals known (to the State of California) to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

•Lead, from lead-based paints

•Crystalline silica from bricks, cement and other masonry products

•Arsenic and chromium, from chemically treated lumber

For further information, consult the following sources:

http://www.osha.gov/dsg/topics/silicacrystalline/index.html

http://www.cdc.gov/niosh/docs/96-112/

http://oehha.ca.gov/prop65/law/P65law72003.html

http://www.dir.ca.gov/Title8/sub4.html

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 the dust masks that are specially designed to filter out microscopic particles. Where use of a dust extraction device is possible, it should be used. To achieve a high level of dust collection, use an industrial vacuum cleaner.

6

CAB COMBO WORKSHOP	SAFETY

ELECTRICAL REQUIREMENTS AND GROUNDING INSTRUCTIONS

In order to prevent potential electrical shock and injury, the following electrical safety precautions and symbols should be followed at all times!

In case of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.

•Do not modify the plug provided – if it will not fit the outlet; have the proper outlet installed by a qualified electrician.

•Improper connections of the equipment-grounding conductor can result in a risk of electric shock. The equipment-grounding conductor is the wire that has a green outter surface, with or without yellow stripes. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal.

•Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded.

•Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool’s plug.

•Repair or replace a damaged or worn cord immediately.

This tool is intended for use on a circuit that has an outlet that looks like the one shown in Sketch A. The tool has a grounding plug that looks like the plug illustrated in Sketch A. A temporary adapter, which looks like the adapter illustrated in sketches B and C, may be used to connect this plug to a 2-pole receptacle as shown in Sketch B, if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician. The green-colored rigid ear, plug, and the like, extending from the adapter, must be connected to a permanent ground, such as a properly grounded outlet box.

Note: Use of a temporary adapter is not permitted in Canada.

To reduce the risk of electrocution, keep all connections dry and off the ground.

A Ground Fault Circuit Interrupter (GFCI) should be provided on the circuit(s) or outlet(s) to be used for this power tool. Receptacles are available, having built-in GFCI protection, and may be used for this measure of safety.

When using an extension cord, the GFCI should be installed closest to the power source, followed by the extension cord, and lastly, the saw.

				Metal Screw
	Grounding		(A)	Cover of
				Grounded	(B)
	Pin
				Outlet Box
		ADAPTER
			Grounding
		(C)	Means	Grounding
				Pin	(D)

Circuit and Adapter Information

7

Drip Loop

CAB COMBO WORKSHOP	SAFETY

ELECTRICAL REQUIREMENTS AND GROUNDING INSTRUCTIONS

To avoid the possibility of the appliance plug or receptacle getting wet, position the tool to one side of a wall mounted receptacle. This will prevent water from dripping onto the receptacle or plug. A “drip loop," shown in Fig 2, should be arranged by the user to properly position the power cord relative to the power source.

The “drip loop" is the part of the cord below the level of the receptacle, or the connector, if an extension cord is used. This method of positioning the cord prevents the travel of water along the

power cord and coming in contact with the receptacle.

If the plug or receptacle gets wet, DO NOT unplug the cord. Disconnect the fuse or circuit breaker that supplies power to the tool. Then unplug and examine for presence of water in the receptacle.

Use only extension cords that are intended for outdoor use. These

extension cords are identified by a marking “Acceptable for use with outdoor appliances; store indoors while not in use." Use only extension cords having an electrical rating not less than the rating of the product. Do not use damaged extension cords. Examine extension cords before using and replace if damaged. Do not abuse extension cords and do not yank on any cord to disconnect. Keep cords away from heat and sharp

edges. Always disconnect the extension cord from the receptacle before disconnecting the product from the extension cord.

To reduce the risk of electrocution, keep all connections dry and off the ground. Don't touch the plug with wet hands.

Use of undersized extension cords will result in low voltage to the motor that can result in motor burnout and premature failure. Barranca Diamond warns that equipment returned to us showing signs of being run in a low voltage condition, through the use of undersized extension cords, will be repaired or replaced totally at the customer's expense. There will be no warranty claim.

To choose the proper extension cord:

•Locate the length of extension cord needed in Table below.

•Once the proper length is found, move down the column to obtain the correct AWG size required for that length of extension cord.

EXTENSION CORD LENGTH

Nameplate			115V	25'	50'	75'	100'	150'	200'
Amperes			250V	50'	100'	150'	200'	300'	400'
0 - 5				16	16	16	14	12	12
5.1	-	8		16	16	14	12	10	•
8.1	-	12		14	14	12	10	•	•
12.1 - 15				12	12	10	10	•	•
15.1 - 20				10	10	10	•	•	•

8

CAB COMBO WORKSHOP		SPECIFICATIONS
CAB COMBINATION WORKSHOP SPECIFICATIONS
Part #8300011	Carbide wheels and diamond belts
Part #8300012	Diamond wheels and diamond belts
Part #8300010	Carbide configuration without motor, GFCI, switch & base board
Part #8300013	Diamond configuration without motor, GFCI, switch & base board
Part #8300014	No wheels, belts, blade, GFCI, switch, motor, base board or polishing
supplies
Horsepower	1/3 HP
Motor Voltage/Frequency	110 volt/60 Hz
Amperage	5.8 Amps
Motor RPM	1725
Motor Arbor Diameter	1/2"
Duty	Continuous, automatic thermal protection shut-off
Motor Arbor Bearings	Ball bearings, permanently sealed
Blade Capacity	6" diameter
Saw Lubricant	Oil or water with rust inhibitor (Tool Cool)
Motor and Shaft Pulley	2" OD x 5/8" bore (shaft) and 2" OD x 1/2" bore (motor)
Shaft Bearings	Permanently sealed 5/8" OD shaft ball bearings
Blade Arbor Flanges	2" OD x 5/8" bore aluminum
Maximum Depth of Cut	Not to exceed 1" for most cuts
Brazed Diamond Wheel	80 and 200 grit
Diamond Resin Belts	400, 600, 1200 and 3000 grit 6" x 1-1/2" wide belt size
Expandable Rubber Drum	6" x 1-1/2" wide x 5/8" arbor
Shaft Type	5/8" precision-machined stainless steel
Wheel and Blade Flanges	Aluminum 2" OD x 5/8" bore
Wheel Spacers	7/8" OD x 5/8" ID aluminum (length varies for wheels and drum)
Convex Polishing End Hub	6" aluminum hub disc with 5/8"-11 right hand thread

Lubricant capacity of reservoir tank: 1/4 gallon will cover 1/4" of 6" blade.

Pump: MK Submersible pump (part #155987-VP), variable flow control with 1/4" ID tubing.

Water Control Valves: 3 stainless steel control valves, brass lever cock valve with barb for 1/4" ID tubing mounted on rear of the hood.

ON/OFF Switch Box: Lever operated switch box and pigtail female plug receptacle for submersible pump.

Standard Polishing Supplies: Three 6" Polytex pads, three diamond paste syringes (5 grams ea.), diamond paste (8,000, 14,000 and 50,000 grit), 6" leather buffing pad, 100 grit green silicon carbide blade sharpening stick (1" x 1" x 6"), 3M On-Off cement, submersible pump, 1/4" ID clear tubing, 3/8" ID clear tubing and GFCI.

9

CAB COMBO WORKSHOP	SETup

CONTENTS

In the shipping crate, you will find one Barranca Diamond Cab Combo Workshop, one 6" x 0.020 x 5/8" 303 Pro diamond blade, one Ground Fault Circuit Interrupter (GFCI) and one 1" x 1" x 6" sharpening stick.

If included as part of your specific order you will also find a variety of accessories.

UNPACKING

Your Cab Combo Workshop has been shipped from the factory thoroughly inspected and tested. Remove the crating material (wood and plastic) from the baseboard and around the machine carefully using Phillips and standard screwdrivers, and a box cutter knife. Any accessories should be removed from the unit and put aside.

TRANSPORT

For safe transport, lubricant should be removed from the saw tank coolant and wheel reservoirs of the Cab Combo Workshop. Removal of the 6" diamond blade is recommended to prevent damage during transport.

10

CAB COMBO WORKSHOP	SETup

INSTALLATION OF BLADE

Remove the saw table by unscrewing the four flat-head machine screws (fig 1) that secure the table to the reservoir tank. Remove the saw table and the cork gasket installed between the saw table and reservoir tank.

Remove the diamond blade from its carton and mount on the 5/8" blade arbor between the two aluminum flanges (fig 2 & 3) with the concave sides of the flanges facing the blade (fig 4).

Fig 1 - Four flat-head machine screws Fig 2 - Inner flange on shaft	Fig 3 - Outer flange and nut installed
secure the saw table to the reservoir	on shaft
tank

A 5/8"-18" left-hand fine-thread jam nut secures the flanges and blades to the arbor shaft. When installing the blade, use an adjustable wrench to turn the nut counterclockwise to tighten the nut against the arbor flange (fig 5). Do not over-tighten the jam nut.

Fig 4 - Concave side of flange	Fig 5 - Tightening the blade on the
	arbor shaft

The included 303 Pro diamond blade is manufactured to cut in a petroleum, mineral, or synthetic water-soluble lubricant. Although water can be used with the Cab Combo Workshop, it is not recommended as the steel arbor shaft and blade core can rust. In addition, poor sawing performance and short blade life can result. If water must be used, it is recommended that a rust inhibitor be added, such as Tool Cool (8 oz. to 1 gallon water or one tablespoon per tank).

11

CAB COMBO WORKSHOP	SETup

INSTALLATION OF BLADE (continued)

Fill the coolant reservoir so that the lubricant fluid covers the bottom 1/4" of the blade (fig 6). Do not overfill the oil reservoir, as excess fluid will result in unnecessary spraying of fluid while sawing, possibly causing damage to the arbor bearings and motor. Once the lubricant has been added, position the cork gasket on top of the reservoir (fig 7) and reattach the saw table with the four mounting screws (fig 8).

Fig 6 - Fill the coolant reservoir so that the lubricant fluid covers the bottom 1/4" of the blade

Fig 7 - Cork tank gasket in place prior to mounting saw table

Fig 8 - Attach the saw table by installing and tightening the 4 flat head machine screws

12