Norton JCW 600 Operating Instructions Manual

JCW 600

OPERATING INSTRUCTIONS

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Declaration of conformity

The undersigned manufacturer:

SAINT - GOBAIN ABRASIVES S.A.

Declares that this product:

190, BD J.F. KENNEDY
L- 4930 BASCHARAGE

Masonry Saws:

is in conformity with the following Directives:

• European Machinery Directive 2006/42/EC

• “LOW VOLTAGE" 2006/95/EC

• Electromagnetic Compatibility Directive 2004/108/EC

and European standard:

• EN 12418 – Masonry and stone cutting-off machines – Safety

JCW 600 1-30-1 230V

Pierre Mersch

Business Manager Machines Europe

Code:

70184630306

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JCW 600

OPERATING INSTRUCTIONS

1 Basic Safety Instructions 6

1.1 Symbols 6

1.2 Machine plate 7

1.3 Safety instructions for particular operating phases 7

2 Machine description 8

2.1 Short description 8

2.2 Purpose of use 8

2.3 Layout 8

2.4 Technical Data 10

3 Assembly and commissioning 11

3.1 Tool assembly 11

3.2 Feet and conveyor cart assembly 11

3.3 Electrical connections 12

3.4 Starting the machine 12

3.5 Water cooling system 12

4 Transport and storing 13

4.1 Securing for transport 13

4.2 Transport procedure 13

4.3 Long period of inactivity 13

5 Operating the machine 14

5.1 Site of work 14

5.2 Cutting methods 14

6 Maintenance and servicing 16
7 Faults: causes and cures 17

7.1 Fault-finding procedures 17

7.2 Trouble-shooting guide 17

7.3 Circuit diagram 18

7.4 Customer service 19

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1 Basic Safety Instructions

The JCW 600 is exclusively designed for the cutting of construction products mainly on construction
sites.
Uses other than the manufacturer's instructions shall be considered as contravening the
regulations. The manufacturer shall not be held responsible for any resulting damage. Any risk shall
be borne entirely by the user. Observing the operating instructions and compliance with inspection
and servicing requirements shall also be considered as included under use in accordance with the
regulations.

1.1 Symbols

Important warnings and pieces of advice are indicated on the machine using symbols. The following
symbols are used on the machine:

Read operator’s instructions Ear protection must be worn

Hand protection must be worn Eye protection shall be worn

Rotation direction of the blade Danger: risk of cut

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1.2 Machine plate

Important data can be found on the following plate located on the machine:

Machine Model Machine Code

Weight

Year of production

Maximum blade diameter

Machine type Serial number Power Safety standard Blade speed

1.3 Safety instructions for particular operating phases

Before commencing work

• Before commencing work, make yourself familiar with the working environment at the place of
use. The working environment includes: obstacles in the area of work and manoeuvre, the
firmness of the floor, necessary protection at the site relating to public thoroughfares and the
availability of help in the event of accidents.

• Site the machine on an even, firm and stable base!

• Check for correct mounting of the blade regularly.

• Immediately remove damaged or badly worn blades, as they endanger the operator whilst

rotating.

• The material to be cut must be held securely in place on the conveyor cart to allow no
movement during cutting operation.

• Always cut with the blade guard in position.

• Only fit NORTON diamond blades to the machine! The use of other tools can damage the

machine!

• Read the blades’ specifications carefully to choose the correct tool for your application.

• Attention is drawn to the use of BS2092 safety goggles in conformity with specified Processes

No.8 of the Protection of Eyes Regulation 1974, Regulation 2(2) Part 1.

Electrical powered machine

• Always turn off the machine and separate it from the main source of electricity before any work
on the machine is done.

• Make all electrical connections securely to eliminate contact of live wires with spray water or
dampness

• When the machine is used with water, it is IMPERATIVE that you earth the machine properly.
Let a qualified electrician check in case of doubt.

• In case of emergency, you can stop the machine by pushing on the front cover of the switch.

• In the event of the machine breaking down or stopping for no apparent reason, switch off the

main electricity supply. Only a qualified electrician is allowed to investigate the trouble and
remedy the fault.

Bore diameter

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2 Machine description

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Any modification, which could lead to a change in the original characteristics of the machine, may
be done only by Saint-Gobain Abrasives who shall confirm that the machine is still in conformity
with the safety regulations.

2.1 Short description

The JCW 600 Masonry saw is designed for durability and high performance for onsite wet and dry
cutting operations of a wide range of masonry, refractory and natural stone products.
As with all other NORTON products, the operator will immediately appreciate the attention given to
detail and quality of materials used in construction. The machine and its component parts are
assembled to high standards assuring long life and minimum maintenance.

2.2 Purpose of use

The machine is designed for wet and dry cutting of a large range of building and refractory
materials, or tiles. It is not designed for cutting wood or metals.

2.3 Layout

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Frame and feet (1)

The frame is made of a jig-welded reinforced steel construction to ensure perfect rigidity. 4
removable legs fit into housings welded on frame sides and locked into place with locking screws.

Cutting head (2)

Spring loaded jig-welded steel console. The motor fixing points and the pivot are machined for
perfect fit. A locking system allows straight-through cutting without any other accessory.

Blade guard (3)

Jig-welded steel construction with 400mm-diameter blade capacity, which offers maximum operator
protection and increased visibility of the work piece.
Incorporated in the blade guard is an outer metal cover, which can be easily opened to allow easy
access to shaft for inspection and blade replacement when motor is switched off, while fully
protecting the blade when in operation.

Blade shaft (4)

Precision-machined blade shaft, held in ballbearings and is driven by a heavy-duty V-section drive
belt. The blade shaft assembly is completely enclosed in a cutting head console, accessible for
inspection by way of a removable plate. The removable blade flange is tightened by means of a
hexagonal nut.

Conveyor cart (5)

Steel welded construction with non-slip top. The machine guide system permits precise cuts to be
made by virtue of four roller sheaves set at an inclination to compensate for wear.
The nylon-plastic sheaves and sealed-bearings permit easy operation. The variable angle guide-a­cut and the large surface area of the conveyor cart permits precise positioning of the material.

Water cooling system (6)

The coolant system comprises:

• A powerful, submersible mechanical water pump.

• Plastic suction pipe delivering the water from the water pan to the cutting head.

• A large capacity water pan supplied with drain plug.

• A water-tap, fitted to the blade guard, permitting controlled water flow.

• Two water nozzles located inside the blade guard ensure adequate flow of water to both sides

of the cutting blade.

• A water curtain, fixed to head axle restricts water spray and minimises water loss.

Electrical Motor (7)

The electric motor has an overload protection. Thermal overload tripping can occur for two reasons:
tripping under light load if connection is incorrect, and tripping under heavy load if motor has been
overloaded.
The ON-OFF switch also serves as emergency stop. The pump switch is located on the right side of
the main switch. Low voltage trigger (NVR) built in the switch prevents the motor to restart for
example after a power cut.

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2.4 Technical Data

Electric motor 2,2 kW 230V with thermal overload protection

Electric motor protection IP54
Max. blade diameter 400 mm
Bore 25,4 mm
Rotation speed of the blade 2700 min-1
Flange diameter 95 mm
Cutting depth mm 150 mm (without reversing the material)
Sound pressure level 78 dB (A) (ISO EN 11201)
Sound energy level 89 dB (A) (ISO EN 3744)

Max. cutting length mm 600 mm
Table dimension (LxW) 460x400 mm
Machine dimensions without feet

(LxWxH)
Machine dimensions with feet

(LxWxH)
Weights

Machine cpl. 97 kg
Ready for use (with water) 130 kg

1390x530x800 mm

1390x750x1480 mm

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3 Assembly and commissioning

The machine is delivered fully equipped (although without diamond blade). It is ready for operation
assembly the diamond blade, the feet and the conveyor cart and after connection to the appropriate
power supply.

3.1 Tool assembly

Only NORTON blades with a maximum diameter of 400 mm can be used with the JCW 600.
All tools used must be selected with regard to their maximum permitted cutting speed for the
machine’s maximum permitted rotation speed.
Before mounting a new blade into the machine, switch off the machine and isolate it from the main
source of electricity.

To mount a new blade, follow these steps:

• Open the shaft vent cover on the blade guard.

• Loosen the hexagonal nut on the blade shaft, which holds the removable outer flange.

• Remove the outer flange.

• Clean the flanges and blade shaft and inspect for wear.

• Mount the blade on arbor ensuring that direction of rotation is correct. Wrong direction of

rotation blunts the blade quickly.

• Replace outer blade flange.

• Tighten hexagonal nut with spanner supplied for this purpose.

• Shut the vent cover.

The blade bore must correspond exactly to the diameter of the blade shaft. Cracked or damaged
bore is dangerous for the operator and for the machine.

3.2 Feet and conveyor cart assembly

Feet and conveyor cart are located in the water pan. Place the four feet in the four openings on
each corner of the frame. Tighten the four locking screws.
Place the conveyor cart on the guiding rails with the material stop facing the operator.

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3.3 Electrical connections

Check that,

• the voltage/phase supply corresponds to the information indicated on the motor plate.

• Available power supply must have ground connection in conformity with safety regulations.

• The connecting cables should have at least a 2.5mm2-section per phase.

3.4 Starting the machine

Open the cover on the switch and press the green button to start the machine. Either press on the
red button or directly on the switch cover to stop the machine.

3.5 Water cooling system

Fill the water pan with clean water to approximately 2cm from top (ensure that bottom of pump is
fully immersed in water).
Open the water-tap on blade guard (note that handle on water-tap should be in line with water-flow).
Ensure that water is flowing freely in the circuit and is delivered adequately to both sides of the
blade, as insufficient water supply may result in premature failure of the diamond blade.
The water pump must never run without water. Always make sure that there is enough water in the
pan and refill if necessary.
In case of frost, empty the water cooling system from its water.

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4 Transport and storing

4.1 Securing for transport

Before transporting the machine, always remove the blade and empty the water pan. Also remove
the conveyor cart, as it can be dangerous while you move the machine.

4.2 Transport procedure

Two people are necessary to move the machine. The machine can be moved with or without its
feet. Always remove feet while transporting the machine in a van and a truck. The machine does
not have lifting hooks. You can roll the machine on the floor using the wheels at the back of the
machine.

4.3 Long period of inactivity

If the machine is not going to be used for a long period, please take the following measures:

• Completely clean the machine

• Loosen the drive belts

• Empty the water system

• Take the water pump out of the slurry and clean it thoroughly.

The storage site must be clean, dry and at a constant temperature.

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5 Operating the machine

5.1 Site of work

5.1.1 Siting the machine

• Remove from the site anything, which might hinder the working procedure!

• Make sure the site is sufficiently well lit!

• Observe manufacturer's conditions for connecting to power supplies!

• Place electric cables in such a way that damage by the device is excluded!

• Make sure you have a continual adequate view of the working area so you can intervene in the

working process at any time!

• Keep other staff out of the area, so you can work securely.

5.1.2 Space required for operation and maintenance

Leave 2 m in front of the machine and 1,5 m around it for usage and maintenance of the M400.

5.2 Cutting methods

To use the machine correctly, you must face it with one hand on the handle of the cutting head, and
the other on the conveyor cart. Always keep your hands away from the moving blade. Open the
switch cover and press the green button to start the machine. To stop either use the red button or
press directly on the switch front cover.

5.2.1 Full depth or fixed cutting

In full depth or fixed cutting, the cutting head is locked in a fixed position and the material is pushed
into it as shown.

• Lower the cutting head to the desired cutting depth (in “through cutting”, lower cutting head until
blade periphery reaches max. 3mm under the surface of the conveyor cart) by means of the
handle on the blade guard

• Fix position by tightening the clamping device

• Put material on conveyor cart

• Push the conveyor cart slowly and without undue pressure towards the rotating blade and cut

the material as shown on the picture.

NOTE: While recommended, it is not absolutely necessary to lock the cutting head into a given
depth position when jam cutting. The desired cutting depth can be maintained by holding firmly the
depth feed handle on the blade guard. If the full depth of cut requires excessive pressure (on very
dense material e.g.) make 2 or 3 shallow cuts.

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5.2.2 Multiple step cutting

Multiple step cutting consists of moving the conveyor cart with the material to be cut back and
forward under the rotating blade,

• Place the material to be cut on the conveyor cart firmly against the guide-a-cut and the
backstop, keeping the hands well away from the blade.

• Move conveyor cart forward near the blade and pull down the cutting head until blade is lowered
to a point where it will lightly contact the surface of the material.

• Then pass the material beneath with rapid full length strokes, taking a shallow cut
(approximately 3 mm deep as shown on the picture) on the forward. On the backward stroke, lift
the blade just clear over the cutting line.

• Complete each rapid stroke backward and forward by passing the material beyond the centre of
the blade before starting the reverse movement of the conveyor cart.

NOTE: the harder the material, the more rapid should be the forward and backward strokes.
Step cutting lessens the area of the blade circumference in contact with the material, keeping the
blade cool, running free and cutting at peak efficiency.

5.2.3 General advice for the cutting

• Material weight under 15 kg and having dimensions smaller than 500x500x150mm can be cut
with the machine.

• Before commencing work make sure tools are firmly seated!

• Select the right tools as recommended by the manufacturer depending on the material to be

worked, the working procedure (dry or wet cut) to be carried out and the required efficiency.

• Apply cooling water continuously whilst cutting and in good time! Make sure the water pan
contains enough water.

• When dry cutting, ensure sufficient dust extraction and wear a dusk protection mask!

• When cutting work is finished, close the water-tap so you can remove the cut pieces from the

conveyor cart without getting wet.

• If the thermal protection trips, reactivate the motor by pushing on the black button located on
the motor and wait until the motor has cooled down before starting the machine again.

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6 Maintenance and servicing

To ensure a long-term quality from the cutting with the M400, please follow the maintenance plan
below:

Begin of the day

During the changing of tool

End of the day

or more often if required

Every week

After a fault

Whole machine

Flange and blade fixing devices Clean
Belts tension Check and adjust
Motor cooling fans Clean
Water pump Clean
Water pan Clean
Water hoses and nozzles Clean
Water pump filter Clean
Cart guiding bars Clean
Motor housing Clean
Reachable nuts and screws Tighten up

Visual control (general aspect,
watertightness)

Clean

Maintenance of the machine

Always perform the maintenance of the machine with the machine isolated from the electrical
supply.

Lubrication

The M400 uses life-lubricated bearings. Therefore, you don’t need to lubricate the machine at all.

Cleaning of the machine

Your machine will last longer if you clean it thoroughly after each day of work, especially water
pump, water pan (which can be removed for easy cleaning), motor and blade flange.

Adjustment and replacement of the belts

To adjust the belts, firstly remove the belt guard by unscrewing the 4 nuts. Loose the 4 motor bolts
and shift the motor by using the two screws on the side.
To replace the belts, move the motor forward on the cutting head. Adjust the belts and retighten
them by shifting the motor to the rear of the machine.
Always use a matched set of belts. Do not replace single belts.

After a damage

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7 Faults: causes and cures

7.1 Fault-finding procedures

Should any fault occur during the use of the machine, turn it off, and isolate it from the electrical
supply. Any works dealing with the electrical system or supply of the machine can only be carried
out by a qualified electrician.

7.2 Trouble-shooting guide

Trouble Possible source Resolution
Motor is not running

Blade is not turning Belts not tightened or defective Check the belts tension and

Motor stops during the cutting,
but can be restarted after a
short period (overload
protection)

No electricity Check the electrical supply

(fuse for example)

Connection cable section too
small

Defective connection cable Change connection cable

Defective switch CAUTION : can only be solved

Defective motor Change motor or contact motor

Cutting advance too quick Cut slowly

Blade is blunt or glazed Sharpen the blade in

Change connection cable

by qualified electrician

manufacturer

change them if needed

calcareous stone

No water on the blade

Defective blade Change blade

Wrong blade specification for
the application

Not enough water in the pan Refill the water pan
Water tap is closed Open tap on blade guard
Water supply system is blocked

up
Water pump is not working

Change blade

Clean water supply system

• Check if pump pulley is
driven by the belts

• Change the pump

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7.3 Circuit diagram

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7.4 Customer service

When ordering spare parts, please mention:

• The serial number (seven digits).

• The code of the part.

• The exact denomination.

• The number of parts required.

• The delivery address.

• Please indicate clearly the means of transportation required such as "express" or "by air".

Without specific instructions, we will forward the parts through the means which seem
appropriate to us --- but which is not always the quickest way.

Clear instructions will avoid problems and faulty deliveries.
If not sure, please send us the defective part.
In the case of a warranty claim, the part must always be returned for evaluation.
Spare parts for the motor can be ordered with the manufacturer of the motor or with their dealer,
which is often quicker and cheaper.

This machine has been manufactured by Saint-Gobain Abrasives S.A.

190, Bd J.F.Kennedy
L- 4930 BASCHARAGE
Grand-Duché de Luxembourg.
Tel. : [phone]
Fax : [phone]

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Guarantee can be claimed and technical support obtained from your local distributor where
machines, spare parts and consumables can be ordered as well:
Benelux and France:
From Saint-Gobain Abrasives S.A.
Free telephone numbers:
Belgium : 0 800 18951
France: 0 800 90 69 03
Holland: 0 8000 22 02 70
e-mail: [e-mail]

Czech Republic

Norton Diamantove Nastroje Sro
Vinohrdadska 184
CS-13000 PRAHA 3
Tel: [phone]
Fax : [phone]
e-mail : [e-mail]

United Kingdom

Saint-Gobain Abrasives Ltd.
Doxey Road
Stafford
ST16 1EA
Tel : [phone]
Free fax : [phone]
e-mail : [e-mail]

Austria

Saint-Gobain Abrasives GmbH
Telsenberggasse, 37
A-5020 SALZBURG
Tel : [phone]
Fax : [phone]
e-mail: [e-mail]

Germany

Saint-Gobain Diamond Products GmbH
Birkenweg 45-49,
D-50389 WESSELING
Tel : [phone]
Fax : [phone]
e-mail: [e-mail]

Spain

Saint-Gobain Abrasivos S.A.
C/. Verneda del Congost s/n
E-08160 MONTMELó (Barcelona)
Tel: [phone]
Fax: [phone]
e-mail:[e-mail]

Hungary

Saint-Gobain Abrasives KFT.
Banyaleg Utca 60B
H-1225 BUDAPEST
Tel: ++36 1 371 2250
Fax: ++36 1 371 2255
e-mail: [e-mail]

Poland

Saint-Gobain Diamond Products Sp.zO.O.
AL. Krakowska 110/114
PL-00-971 WARSZAWA
Tel: [phone]
Tel/Fax: [phone]
e-mail: [e-mail]

Italy

Saint-Gobain Abrasivi S.p.A.
Via per Cesano Boscone, 4
I-20094 CORSICO-MILANO
Tel: [phone]
Fax : [phone]
e-mail : [e-mail]

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SAINT-GOBAIN ABRASIVES

190, Bd. J. F. Kennedy
L-4930 BASCHARAGE
LUXEMBOURG

Tel.: ++352 50401-1
Fax: ++352 501633

e-mail: [e-mail]

www.construction.norton.eu

09.12.2008

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