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SAINT-GOBAIN NORTON clipper CTC1020XL Owner's Manual

Wet tile saw 10”
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OWNER'S MANUAL
WET TILE SAW 10"
Model: CTC1020XL

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Summary of Contents for SAINT-GOBAIN NORTON clipper CTC1020XL

  • Page 1 OWNER’S MANUAL WET TILE SAW 10” Model: CTC1020XL...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Table of Contents ....................1 Safety Precautions ....................4-8 Dust and Silica Warning ......................6 Machine Lifting Points ......................8 SPECIFCATIONS & Features ................. 9-10 CTC102XL Specifications ....................... 9 Optional Accessories ......................11 Unpacking, Assembly, & Setup................12-16 Blade Guard Blade Assembly ....................

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Operation......................... 21-24 Wet Cutting Do’s & Don’ts ...................... 24 Dry Cutting Do’s & Don’ts ....................... 24 Saw Maintenance & Trouble Shooting ..............25-42 Trouble Shooting & Maintenance Chart .................. 25-26 Belt Replacement ........................27 Belt Tensioning ........................27-28 Belt Replacement ........................

  • Page 5: Safety Precautions

    SAFETY PRECAUTIONS Important warnings and pieces of advice are indicated on the machine with icons. HAZARD ICONS Fuel (gasoline) is extremely flammable, and its vapors can explode if ignited. Store gasoline only in approved containers, in well-ventilated, unoccupied approved areas, and away from sparks or flames. Do not fill the fuel tank while the engine is hot or running.
  • Page 6 SAFETY PRECAUTIONS Important warnings and pieces of advice are indicated on the machine with icons. SAFETY ICONS Read OSHA and ANSI B7.1. Read operator’s instructions. Visit the industry safety page: www.safety.UAMA.org Eye protection must be worn. Ear protection must be worn. Hand protection must be worn.

  • Page 7: Dust And Silica Warning

    SAFETY PRECAUTIONS DUST AND SILICA WARNING Grinding/cutting/drilling of masonry, concrete, metal, and other materials can generate dust, mists and fumes containing chemicals known to cause serious or fatal injury or illness, such as respiratory disease, cancer, birth defects or other reproductive harm. If you are unfamiliar with the risks associated with the particular process and/or material being cut or the composition of the tool being used, review the material safety data sheet and/or consult your employer, the material manufacturer/supplier, governmental agencies such as OSHA and NIOSH and other sources on...
  • Page 8 SAFETY PRECAUTIONS 1. Before mounting any blade on the saw, the blade should be inspected for any damage which might have occurred during shipment, handling, or previous use. 2. The blade collars and arbors should be cleaned and examined for damage before mounting the blade.
  • Page 9 SAFETY PRECAUTIONS Lifting Points DO NOT Lift by Cutting  Head or Blade Guard  DO NOT Lift by  Cutting Table  Lift Here  Lift Here  CTC1020XL Lift Points  The best lifting point is from the underside of the lip of the water pan which is highlighted with GREEN arrows on both sides of the machine or at the front and back. ...

  • Page 10: Specifcations & Features

    SPECIFICATIONS & FEATURES 1. A Powerful 2 HP brush motor makes cutting easier and quicker. 2. The Automatic Thermal Overload Protection system protects your saw from power surges and overheating. 3. The high fiber plastic water tray withstands even the toughest jobs, yet it is extremely easy to remove and install.
  • Page 11 SPECIFICATIONS & FEATURES Back Splash  Powerful  Motor  Power Switch  Cutting Table  Water Pan  Tray Lock  Heavy Duty Back Stop  CTC1020XL Features Description 2.0 HP (1.41 kW) 115v/60Hz/1 Phase motor provides long life and is powerful Powerful Motor enough to cut any material Enclosed in a heavy duty all metal housing with thermal reset and electrical Power Switch receptacle for powering the water pump Vibration Reducing nonslip rubber cutting with 45°...

  • Page 12: Optional Accessories

    OPTIONAL ACCESSORIES Optional Accessories Description Type Image 70184682710 RIP GUIDE45/90 CTC/YTM7 70184680905 WRENCH UNIVERSAL YTM1015 Optional Accessories: 70184643045 STAND WITH WORKTABLE MITER BLOCK 70184680897 (For Miter Cutting Includes Mounting Hardware) GUIDE ADJUSTABLE ANGLE GUIDE 70184680907 (Includes Mounting Hardware) SIDE EXTENSION TABLE W/HARDWARE 70184632401 CTC1020XL GFCI PLUG NEMA 5-15P x NEMA 5-15R...

  • Page 13: Unpacking, Assembly, & Setup

    UNPACKING, ASSEMBLY & SET-UP Open the container, carefully lift the saw by the saw frame handles and place it on a flat, level working area. Be certain that you have the following items before you discard the container. • Saw •...
  • Page 14 UNPACKING, ASSEMBLY & SET-UP 5. Place the Ø10" blade onto the shaft, make sure that the directional arrow is pointing in the direction of the shaft rotation. Lift up the Blade Guard, then fasten the blade tightly using the outer Flange and Blade Shaft Nut. Cutting Head ...

  • Page 15: Blade Installation

    UNPACKING, ASSEMBLY & SET-UP Blade Installation 1. Raise the blade guard to the highest position and tighten the blade guard adjustment knob. 2. Remove the blade shaft nut and outer flange. 3. Verify the direction of rotation of the Diamond Blade and match it to the CTC1020XL.

  • Page 16: Using The Cutting Table

    UNPACKING, ASSEMBLY & SET-UP Optional Side Extension (6)  Using Cutting Table 2  3  1. The ruler guide (1) has inches marked along the front to allow convenient measurements and precision cuts. 2. The cutting table dimensions are approximately 16” x 16". When the optional side extension table is installed, the working area of the cutting 5 ...

  • Page 17: Preforming Miter Cuts

    UNPACKING, ASSEMBLY & SET-UP Performing miter cuts To make miter cuts, an optional 70184680897 miter block must be purchased. 1. Place the lip of the miter block on the ruler guide with the threaded knob facing you. 2. Position the miter block so that the tile lays flat against the block. Rest its left-most edge within the vertical channel of the cutting table.

  • Page 18: Electrical

    ELECTRICAL CTC1020XL Electrical Motor Specifications: Table 3. Extension Cord Chart Voltage: 115-volt Wire Gauge 115V Max Length Cycles: 60Hz 12 AWG 25' (7.6 m) 10 AWG 50' (15.2 m) Amperage: 15 Amp 8 AWG 75' (22.8 m) Horsepower: 2 HP Watts: 735 watts Motor RPM:...

  • Page 19: General Electrical Trouble Shooting

    GENERAL ELECTRICAL TROUBLE SHOOTING CTC1020XL Wiring Diagram Circuit Breaker During Start Up or Not Cutting:  Verify that the power supply voltage matches the motor name plate voltage Failure to run the motor on the proper voltage will damage the motor and is not covered under warranty.

  • Page 20: Electrical Trouble Shooting

    GENERAL ELECTRICAL TROUBLE SHOOTING • Verify the cutting method. Forcing the Blade into the material is a sign that either the Blade is NOT correct for the material being cut or an inexperienced operator. Let the Blade and Machine work for you do not work for the Blade and Machine.
  • Page 21 GENERAL ELECTRICAL TROUBLE SHOOTING c) Overload Protector (Thermal) issues see Overload Protector (Thermal) Tips page 17. d) Low voltage at the machine see Power Supply page 15 Tripping of Circuit Breaker: a) If tripping while starting machine Circuit Breaker issue: weak, damage, to low amperage b) If tripping while cutting any material: Incorrect blade for the material being cut.

  • Page 22: Operation

    OPERATION Operation The CTC1020XL tile saw is designed to cut tiles, stones, masonry products, bricks, and pavers up to 24” x 24” x 2”. The CTC1020XL should always be used wet if dry cutting use only blades designed for dry cutting and follow all OSHA requirements for dry cutting. 1.
  • Page 23 OPERATION Additional Cutting Features Cutting Table  The Cutting Table features an adjustable ruler guide (1) enable easy aligning and measuring of cuts. The Ruler Gide can be removed for longer tiles and finetuned to ensure accurate measurements of any tile (loose the attachment screws and move left or right to align the center of the blade with the “0”...
  • Page 24 OPERATION Miter Cuts 1. For miter cuts, place the lip of the miter block on the Ruler Guide, with the threaded knobs facing you. 2. Tighten the threaded knobs to secure the miter block in place. 3. Place material onto miter block and you are ready to cut. Cutting Depth The recommended cutting depth is to have the bottom of the diamond blade approximately ¼"...
  • Page 25 OPERATION Wet cutting Blades DO'S Use proper PPE Inspect blades daily for cracks or uneven wear. Always use appropriate blade for material being cut. Inspect arbor shaft for uneven wear before mounting blade. Always use blades with the correct arbor shaft size. Ensure that blade is mounted in the correct direction.

  • Page 26: Saw Maintenance & Trouble Shooting

    SAW MAINTENANCE & TROUBLE SHOOTING Saw Maintenance Maintenance Interval What to do for maintenance and care After every use of the machine Remove dirty water from container.  Remove dirt and mud from the bottom of the container.  Rinse the immersion pump with fresh water to  prevent water pump clogging from residual dirt. After wet cleaning and before using the machine again  Connect the machine to an electric power outlet equipped with  a "GFCI" power breaker. If the safety power breaker cuts off  the electrical power supply, do not try to operate the machine  but have it checked by an authorized dealer first.  Before not using the machine for a prolonged period of time  Clean and lubricate all movable parts.  After not using the machine for a prolonged period of time  Check that the stand is safely fixed.  Check that all screw joints and nuts are fixed.  Check that the roller table is in its guides and that it easily  moves to and from.  With the saw blade removed, switch on the motor for an  instant and switch it off again. If the motor does not run, have  the machine inspected by a qualified electrician.  Check that the immersion pump works properly. Turn on the  cooling water tap and switch the machine on. If the pump does  not give any water or only a little, switch the machine off at  once. Clean the pump or replace if necessary.  Ambient temperature below 32 F (operation in winter)  To prevent the water in the pump and cooling system from  freezing, remove the water after using the machine or when  there will be a long break. Make sure that the cooling system is  entirely drained so that there is no water left inside the pump,  water hose and bearing housing!  Trouble Shooting Problem Possible Cause Solution ...
  • Page 27 SAW MAINTENANCE & TROUBLE SHOOTING Trouble Shooting (continued) Problem  Possible Cause  Solution   Use a Power cord extension cable of Poor machine performance little power   Power  cord/extension cable too  long  or  the  rated  length,  use  a  cable  drum  cable still wound up inside cable drum  with cable fully extended.   Power network is insufficient  Observe the electrical ratings of the machine  and  connect  it  only  to  a power network which complies with these ratings ...

  • Page 28: Belt Replacement

    SAW MAINTENANCE & TROUBLE SHOOTING Belt Replacement 1. Turn off & disconnect the machine from any power supply before proceeding any further. 2. Loosen and remove the four (4) bolts located above and below the belt guard and then remove the belt guard. 3.
  • Page 29 SAW MAINTENANCE & TROUBLE SHOOTING 1  1  4  2  3  Belt Tensioning 1. Unplug the saw from the power supply. 2. Verify that the Power Switch is in the OFF position 3. Remove the belt guard (see #1 in the Figure: Belt Tensioning) by removing all four (4) Belt Guard Retaining screws.

  • Page 30: Belt Replacement

    SAW MAINTENANCE & TROUBLE SHOOTING 9. Reinstall the Belt Guard and tighten all four (4) of the Belt Guard Retaining screws with lock washers and flat washers (see #1 in the Figure: Belt Tensioning). Belt Replacement Belt Replacement 1. Unplug the saw from the power supply. 2.
  • Page 31 SAW MAINTENANCE & TROUBLE SHOOTING 9. Tension the belt by moving the motor away from the blade by turning the Belt Tensioner Screw Clockwise (see #4 in the Figure: Belt Replacement) until 3/8” of deflection is reached in the belt when pushed down on the middle.

  • Page 32: Main Causes Of Belt Failures

    SAW MAINTENANCE & TROUBLE SHOOTING Main Causes of Belt Failures:   Premature Belt failure can be attributed to the following issues: Tension (too much or too little), Pulley  Misalignment, Damaged Pulleys, Improper Handling or Storage, Incorrect Blade Specification for Material  Being Cut, and Cutting Too Deep.  Symptom  Possible Cause  Corrective Action  Too Much Tension  Re‐tension Belts  Belt Breakage  Excessive Shock Load  Reduce Load/ Check Blade Specification  Pulley Out Of Round  Replace Pulley  Too Little Belt Tension  Increase Belt Tension  Excessive Load   For Best Performance Only Cut only 1‐/2” to 2” Per Pass  (Cutting Full Depth)  Burning of Belt  Containments On Belts  Replace Belts and Find Source of Containments  Incorrect Blade Specification  Replace Blade with One Designed For Material Being Cut  Symptom  Possible Cause  Corrective Action  Belt Tearing/Ripping  Pulley Misalignment  Align Pulleys  Belt Rolling Off Pulley ...
  • Page 33 SAW MAINTENANCE & TROUBLE SHOOTING Brush Cap and Carbon Brush  Motor Cover  Located On Back of Motor   CTC1020XL Brush Locations Motor Cover  Motor Cover  Retaining  Hardware  Brush Cap  Brush  Brush  Brush Cap  Motor and Brushes Shown in Exploded View for Clarity 1. Disconnect the power source from the CTC1020XL 2. Verify that the cutting head is horizontal to the work surface and that the depth 3.
  • Page 34 SAW MAINTENANCE & TROUBLE SHOOTING 4. Use a coin or wide blade screwdriver to remove the Carbon Brush Cap. Use care not to damage the Carbon Brush Cap. i. Inspect the Carbon Brush Cap for damage. If the Cap has any signs of damage replace the BRUSH CAP NOTE: Brush Caps are sold individually.

  • Page 35: Bearing Housing Installation

    SAW MAINTENANCE &   TROUBLE SHOOTING 1. Unplug the saw from the power supply. 2. Verify that the Power Switch is in the OFF position 3. Remove the belt guard (see #1 in the Figure: Blade Shaft Housing Exploded View) by removing all four (4) Belt Guard Retaining screws.
  • Page 36 SAW MAINTENANCE & TROUBLE SHOOTING 8. Place the blade shaft set screws into the blade shaft pulley set screw holes. NOTE: Do not tighten. 9. Align the blade shaft pulley to the motor pulley with a straight edge and snug the set screw to the blade shaft pulley.

  • Page 37: Water Pump Maintenance

    SAW MAINTENANCE & TROUBLE SHOOTING c. Make sure that the width of the outside land is equal on the motor and blade shaft pulleys. d. If one of the pulleys is not aligned to the other, it is due to: a).

  • Page 38: Realignment Of Blade To Cutting Table

    SAW MAINTENANCE & TROUBLE SHOOTING 13. NEVER place the water pump or leave the water pump in any slurry, mud, a dirty water pan, or in any debris. 14. If operating in temperatures below 32°F (0°C) do not let the water freeze in the water pump, bearing housing, water hoses, or water tray as damage may occur which is not covered under warranty.
  • Page 39 SAW MAINTENANCE & TROUBLE SHOOTING rail should be replaced Typically a bowing displacement of up to 0.008” (0.2mm) will not a0ect cutting accuracy. Rail Straightness b. If the straight edge touches both edges of the blade initially, but shifts apart as the table travels along the rail, proceed to method 2 below 6.
  • Page 40 SAW MAINTENANCE & TROUBLE SHOOTING Method 2 This procedure corrects another source of misalignment that occurs when the table’s orientation is not parallel with the guide rails. 1. Lift the saw up from the water tray and place it on a flat level surface. Use the universal wrench to loosen (but not remove) the fasteners from either end of both guide rails.
  • Page 41 SAW MAINTENANCE & TROUBLE SHOOTING 2. Remove rubber cap A on the left side of the table (see Figure: Cap Locations). Loosen the exposed lock nut using a 13 mm socket wrench. Use a flat screwdriver to turn the shaft of the roller clock- wise to lower it by approximately 3/8" (9.5mm). (See Figure: Cap Locations) Evenly lift the table up to disengage the guide rollers from the operator’s left side guide rail.

  • Page 42: Leveling The Cutting Table

    SAW MAINTENANCE & TROUBLE SHOOTING Roller and Shim 4. After adding shim(s), mount the table onto the guide rails by reversing the instructions in step 2. Move the rails toward each other to engage the horizontal rollers to the right guide rail as shown in figure 10.
  • Page 43 SAW MAINTENANCE & TROUBLE SHOOTING rollers clockwise. (See figure Cap Locations) This will lower the horizontal rollers to allow room for adjusting the flat rollers. Cap Locations Loosen the socket bolts on the flat roller plate so that the roller can swing freely about one bolt.

  • Page 44: Main Assembly Group

    SAW EXPLODED VIEW Main Assembly Group Main Assembly Group Part # Description Type 70184645723 FRAME WELDMENT CTC1020XL 242064 -TBA- CUTTING HEAD ASSEMBLY CASTING CTC1020XL 242065 70184602084 BLADE GUARD ASSEMBLY CTC1020XL 242066 70184608941 RAIL FOR CUTTING TABLE CTC1020XL (Set of 2) 242067 70184629524 WATER PUMP...

  • Page 45: Cutting Head Group

    SAW EXPLODED VIEW Cutting Head Group Cutting Head Group Part # Description Type -TBA- 242011 MOTOR MOUNTING PLATE CTC1020XL 70184644121 242012 MOT 2HP 115v/60/1 CTC1020XL 242013 70184644928 BELT GUARD CTC1020XL 70184633707 242014 BLADE GUARD SHAFT CTC1020XL -TBA- 242015 BELT GUARD BRACKET CTC1020XL -TBA- 242016 BLADE SHAFT ASSEY CTC1020XL...
  • Page 46 SAW EXPLODED VIEW Cutting Head Group Cutting Head Group Part # Description Type 70184646880 242029 BOOT SWITCH CTC1020XL -TBA- 242030 THERMAL RESET 15A W/BOOT CTC1020XL 70184680858 242031 SWITCH W/BOOT CTC1020XL 70184644930 242032 PULLEY 54mm OD x 16mm ID 1G 70184644931 242033 KEY 5X5X30mm 70184600797...

  • Page 47: Blade Guard Group

    SAW EXPLODED VIEW Blade Guard Group Blade Guard Group Part # Description Type 70184601387 242001 BLADE GUARD CTC102XL -TBA- 242002 RIVET 4X3 242003 242003 BRUSH BLADE GUARD (2) -TBA- 242004 RETAINING CLIP WATER TUBE CTC1020XL -TBA- 242005 WATER BAFFLE PLATE CTC102DXL 70184647427 242006 HOSE 6mm ID X 8mm OD X 95mm...

  • Page 48: Motor Assembly Group

    SAW EXPLODED VIEW Motor Assembly Group Motor Assembly Group Part # Description Type 70184601697 242076 MOUNT BLOCK MOTOR CTC1020XL 70184644121 242077 MOTOR 2HP 115v/60/1 CTC1020XL 300323 SCR M8 X 25 1.25 DIN933 FULL THD 70184624388 70184625602 300241 SCR M8 X 30 1.25 DIN7991 HS C'GINK HEAD 300273 NUT M8 1.25 DIN934 HEX 70184625643...

  • Page 49: Cutting Table Group

    SAW EXPLODED VIEW Cutting Table Group Cutting Table Group Part # Description Type 70184601818 CUTTING TABLE CASTING CTC1020XL 242037 70184694311 WHEEL ROLLER GROOVED SET OF TWO (2) 242038 70184646075 WHEEL CONCNTRIC FLAT ROLLER (1) CTC1020XL 242039 70184601819 RULLER GUIDE CTC1020XL 242040 -TBA- SPRING LOCK ASSEMBLY CTC102DXL...

  • Page 50: Blade Shaft Group

    SAW EXPLODED VIEW Blade Shaft Group Blade Shaft Group Part # Description Type -TBA- BEARING HOUSING BLADE SHAFT CTC1020XL 242052 70184632301 BLADE SHAFT CTC1020XL 242053 -TBA- GASKET RUBBER BEARING HOUSING CTC1020XL 242054 -TBA- WATER CHANNEL COVER CTC1020XL 242055 70184633708 CONNECTOR M10 MALE X 7.5 242056 70184647428 242057...
  • Page 51 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

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