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OPERATING INSTRUCTION

Section 4

4-9

Saw Blade Speed Control Panel

c

d

1. Cutting Pressure Control Dial

2. Saw Blade Down feed Rate Control Dial

Fig 4-2: Cutting Parameters Control Panel

Cutting Parameters Control Panel

1. Cutting Pressure Control Dial

This pressure control valve is used to adjust the cutting force of the blade applying on the cutting
material. When this dial is turned CW (clockwise), the cutting force increase; on the contrary, if this
dial is turned CCW (counterclockwise), then the cutting force decreases.
This control dial is used to control the cutting pressure applied to the material during the cutting
period. Proper cutting pressures are supposed to be chosen to achieve the most effective cutting
conditions when cutting different materials. Turn this dial to a colored position corresponding
cutting material zone.

Page 42

Instruction Manual for AH-250H (B040)

04/12/2014

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Summary of Contents for AH-250H

Page 1: ...INSTRUCTION MANUAL AH 250H Automatic Hitch Feed Metal Cutting Band Saw 415V 280 x 250mm W x H Rectangle B040 Page 1 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 2: ...ocedures for AH 250H TECHNICAL ADVICE SPARE PARTS Please contact the COSEN representative in your local area in case you need any technical advice or if you want to order spare parts Instruction Manual AH 250H Automatic Horizontal Bandsaw Ver 1 Date 09 18 1998 Ver 2 Date 07 01 2003 VER 3 Date 12 01 2010 1995 by COSEN CO LTD R D DIVISION 110 Ching Fu Street Hsin Chu 300 Taiwan R O C Tel 886 3 53321...

Page 3: ...ing accuracy for many years if the procedures for installation operation maintenance and troubleshooting are followed However if there are questions please contact our agent or our factory for the nearest service or sales representative Enough already I hope you find COSEN as incredibly smart as I do If you have any suggestions for improvement please tell us we will appreciate your help again Than...

Page 4: ...G AND INSTALLATION 3 1 INTRODUCTION 3 1 3 2 MOVING THE MACHINE 3 2 3 3 INSTALLATION OF THE MACHINE 3 3 3 3 1 Safety Precautions 3 4 3 3 2 Initial Inspection 3 4 3 3 3 Space Required 3 4 3 3 4 Unpacking 3 6 3 3 5 Equipment Furnished 3 6 3 3 6 Installation Procedure 3 6 Fixing the Machine on the floor 3 7 Machine Leveling 3 7 Installation of Feed Roller 3 7 Cutting Fluid Supply 3 7 Hydraulic Fluid S...

Page 5: ... GUIDE 7 1 INTRODUCTION 7 1 7 2 BAND SAW BLADE SELECTION 7 1 3 7 3 Some Sawing Practices 7 4 7 3 1 Selection of Saw Pitch 7 4 7 3 2 Material Size and Saw Pitch 7 4 8 MAINTENANCE SERVICE 8 1 INTRODUCTION 8 1 8 2 BASIC MAINTENANCE 8 1 8 3 MAINTENANCE SCHEDULE 8 1 Before beginning of work each day 8 2 After ending work each day 8 2 Every monthly maintenance 8 2 Every six months maintenance 8 3 8 4 ST...

Page 6: ...T ASS Y 10 12 13 10 07 DRIVE WHEEL ASS Y 10 14 15 10 08 REDUCER GEARBOX BODY ASS Y 10 16 17 10 09 ELECTRICAL HYDRAULIC CONTROL BOX ASS Y 10 18 19 10 10 WIRE BRUSH ASS Y 10 20 21 10 11 HEAD CYCLINDER ASS Y 10 22 23 10 12 FEED EQUIPMENT ASS Y 10 24 25 10 13 MAINFOLD TAPPET CYCLINDER 10 26 27 10 14 WORK FEED DEVICE 10 28 29 10 15 FEED VISE ASS Y 10 30 31 10 16 MULTI VISE ASS Y 10 32 33 10 17 FEED CYC...

Page 7: ...Section 1 SAFETY RULES Page 7 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 8: ...g when operating the machine They may cause danger if they are caught in a running machine Be sure to confirm that the area around the machine is cleared of people and obstacles every time before starting the machine or operation Page 8 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 9: ...de or remove chips when the saw blade is running It is dangerous if hands or clothing are caught by the running blade Never cut carbon or any other material that produces and disperses explosive dust on this machine Sparks from motors and other machine parts may ignite and explode the air borne dust The machine needs special measures for cutting explosive materials Page 9 Instruction Manual for AH...

Page 10: ... other fire control device near the machine when cutting titanium magnesium or any other material that produces flammable chips Never operate the machine unattended when cutting flammable materials Use roller tables on forward and backward sides of the machine when cutting the long work It is dangerous if the work falls off the machine when the roller tables are not used Page 10 Instruction Manual...

Page 11: ... falls Never start the saw blade unless it has been confirmed that the work is firmly clamped If the work is not securely clamped with the vise pieces will be forced out of the vise during cutting Never touch the running saw blade It is dangerous if your hands or clothing are caught by the running blade Page 11 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 12: ...able It is dangerous if your foot slips on the rollers and you fall Turn off the shop circuit breaker switch before servicing the machine Then post a sign to inform people that the machine is under maintenance Page 12 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 13: ...Section 2 GENERAL INFORMATION Page 13 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 14: ...o 10 sections Each section covers a specific aspect of the machine This section contains a general description of the machine and other available documentation We are going to introduce this smart machine now 2 2 EQUIPMENT DESCRIPTION This automatic band saw machine is designed based on the guidelines of low cost and high performance It is designed to cut various kinds of materials with the approp...

Page 15: ...iven by main motor HYDRAULIC 0 75 kW 1 HP SAW BLADE 2 2 kW 3 HP MOTOR OUTPUT COOLANT PUMP 0 1 kW 1 8 HP HYDRAULIC OIL SYSTEM TANK CAPACITY 20 L 5 0 gal COOLANT CAPACITY 38 L 9 5 gal MODE HYDRAULICAL Automatic FEEDING LENGTH Max 3600 mm max 141 VISE CONTROL METHOD STATIONARY MOVABLE HYDRAULIC VISE HEIGHT OF WORK BED 550 mm 21 7 NET WEIGHT 1400 kgs 3080 lbs GROSS WEIGHT 1600 kgs 3520 lbs 2100 2150 1...

Page 16: ...out hesitation in the following cases Any emergency situation that would cause severe injury Any abnormal situation or error such as fire etc The button is going to be locked when you press it To unlock it you must pull it Its appearance has red color and rubber material for safe operation We hope you do not press this button inadvertently or otherwise 2 2 4 Noise Level Noise has a major effect on...

Page 17: ...nit 4 Speed reducer 5 Hydraulic motor pump 6 Belt transmissions variable speed motors 7 Blade motor 8 Coolant Pump 9 Drive wheel 10 Parts machine not assembled tightly causing mechanical vibration When your machine is running noise will come out This is a machine electric interface problem that may make people feel uncomfortable Our products pass noise testing under 78 dBA If your machine produces...

Page 18: ...ctuated in operating situations The automation detector is a proximity sensor used to detect the motion of the drive saw wheel Once the saw blade is broken the driven wheel will stop running The sensor will be detecting this problem and then stop the machine The power switch controls the main power of the machine The emergency stop switch on the control panel is a red button with rubber material I...

Page 19: ...se elements under any circumstances except when servicing the machine However even skilled service technicians still have to be very careful when performing repairs or service on the machine with any of these protectors removed It is the responsibility of the user to make sure all these elements is not lost and damaged 2 2 6 Specification of Electrical Equipment Electrical equipment is very import...

Page 20: ...ely than the pulse waveform of the arrester to cause electromagnetic induction The RC compound element is thus considered better in noise elimination Due to the reasons mentioned above mount a RC compound element on each of AC motor AC solenoid and AC control relay 2 3 GUIDE TO THE MANUAL SECTION 1 2 3 10 APPENDIX The instruction manual is divided into ten sections Each section contains important ...

Page 21: ...GENERAL INFORMATION Section 2 2 8 Page 21 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 22: ...Section 3 MOVING INSTALLATION Page 22 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 23: ... carrying and cleaning methods described to keep your machine in the best working condition You can choose any one of the methods described below to move your machine Carrying 1 Use crane to place Carry the machine to its designated location by using a crane and a wire rope sling that can fully withstand the weight of the machine Apply the wire rope sling to the lifting hooks at the rear of the fr...

Page 24: ...he machine When you work together with more than two people it is best to keep contact with each other by voice for safety 2 Use forklift to place Most users choose this method to move their machine because it is easy to set up Make sure that the lifting rod can fully withstand the weight of the machine You must have a qualification license to operate forklift for moving your machine Page 24 Instr...

Page 25: ...rust preventive grease with wiping cloth dampened with cleaning oil or kerosene Apply machine oil to the machine surfaces that are susceptible to rusting NOTE Do not remove the rust preventive grease with a scraper or the like Do not wipe the painted surfaces with solvent 3 3 INSTALLATION OF THE MACHINE This band saw machine has been designed and manufactured in accordance with the latest technica...

Page 26: ...ay prevent your machine electric installation from working properly z Please connect with power supply independently and directly z Please use correct electric capability electric tension 50 60 Mz NOTE cSupply electric power to the machine from a source different from those for welding or other machines that produce electric noise Ground the machine with an independent grounding conductor d Limit ...

Page 27: ...achine Body 6 Hydraulic Unit 2 Electrical Control Box 7 Hydraulic Hose 3 Work Tray 8 Roller Table 4 Cutting Length Preset Device 9 Optional Roller Table 5 Chip Conveyor 10 Fig 3 1 Floor Space Required with Optional Table Page 27 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 28: ...NO MAIN SECTION 1 Machine Body 5 Chip Conveyor 2 Electrical Control Box 6 Hydraulic Unit 3 Work Tray 7 Hydraulic Hose 4 Cutting Length Preset Device 8 Roller Table Fig 3 2 Stander Floor Space Required Page 28 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 29: ...unning Cutting ease and efficiency can be maintained with proper care We list the standard accessories and illustration as follows 1 Tool box 1 pc 2 Grease gun 1 pc 3 Screw drive 2 pcs 4 Open end spanner 3 pcs 5 Hexagon wrench 1 set 6 Chip filings spade only manual type machine 1 pcs 7 Operation manual 1 pcs 3 3 6 Installation Procedure Your machine is easier to install than other brand type Follo...

Page 30: ...ng this procedure Also watch out for your fingers and feet 5 Other machinery may cause vibration or dust for your machine It will prevent machine from working effectively You have to avoid this kind of situation Machine leveling Place spirit levels on the vise slide plates and the work feed table and adjust the left and right and fore and aft level of the machine with leveling bolts NOTE Be sure t...

Page 31: ...t is a new machine If operation new machine the oil tank should be fill hydraulic oil to full level Electrical Connections Power Requirement z Open the electrical enclosure door and connect the power supply cable to the circuit breaker N F B terminals that are indicated by the arrow in the illustration below z Be sure to connect the ground cable to the ground terminal The power supply to your mach...

Page 32: ...e do not anyone or anything near your machine for safety 3 5 RESHIPMENT PROCEDURE We recommend you do the procedures as follows 1 Turn off the power 2 Fix the saw head 3 Pack machine with plastic bag or soft paper to protecting it from dust 4 Pack your machine with bracket carefully and use a crane or forklift to raise it If a crane is used to lift the machine ensure that the lifting cable is prop...

Page 33: ...Section 4 OPERATION INSTRUCTION Page 33 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 34: ...or the warning signal to stop people coming up 4 2 PREPARATION FOR USE The selection of an appropriate saw blade and cutting method is important for cutting work safety and efficiency Select an appropriate saw blade and cutting method by fully considering the work to be cut and the requirements of your job such as cutting accuracy cutting speed economy and safety control Cutting method If you choo...

Page 35: ...fication of failure condition 4 3 1 Control console Control Console Illustration The control console is setting on top of left side of electrical box In figure 4 1 is show all of switch or and botton position therefore operator must understand each switch or and botton function before staring machine The illustration of the control console is shown in the following figure and there are 15 function...

Page 36: ... When the machine is first started in the MANUAL mode and then switched to the AUTO mode the first cut is not counted but the machine automatically operates according to the preset cutting data This function can be used for the machine to automatically cut the work after it trims the end of the work 2 In the automatic mode when the switch is turned to MANUAL during cutting the machine stops on com...

Page 37: ...ckward when the blade motor is running FORWARD mode Press to feed the stock forward The rear vise cannot be moved forward if the front vise and rear vise are both closed The quick approach feeler may be damaged if the rear vise is moved with the work clamped and in contact with the quick approach feeler The button is engaged when number 3 AUTO MANUAL selectswitch is turned to BACKWARD mode Press t...

Page 38: ...ically Fig 4 2 Cutting piece counter The lower number yellow color digital number stands for the number of designated cutting pieces while the upper number white color digital number is the number of workpieces which have been cut in current automatic cutting period NOTE The PRESENT BUTTON GEAR is used to adjust the under number to the designated cutting pieces After the counter reaches the number...

Page 39: ... 3 Feeding Times seletor 15 BLADE SPEED display The blade speed is shown here and the blade speed can be adjusted by stepless cariable speed mechanism NOTE The B S D blade speed display all of data setting by COSEN Machinery Industrial Co Ltd Therefore operator must understand DO NOT CHANGE ANY PARAMETER DATA BY USER Fig 4 4 Blade speed display No Name Remark No Name Remark 1 Display Nb Red LED 6 ...

Page 40: ... It mean is locking all of setting parameters If press It mean is release locking function So user should change before setting parameter DO NOT CHANGE ANY DATA BY USER Press 8 SHIFT key 1sec Change DS1 Millimeters system DS2 British system NOTE Entry to correction mode the display number will flesh If operator is waiting time more than 10 sec not change parameter numeric it should be return to or...

Page 41: ...djust the saw blade speed for different characteristics and shapes of the materials to be cut Cutting Length Preset Device This device is used to preset the required cutting length of a workpiece for automatic cutting When the band wheel is turned clockwise the cutting length of the workpiece is shortened When it is turned CCW counterclockwise the cutting length is lengthened Motion Detector This ...

Page 42: ...cutting material When this dial is turned CW clockwise the cutting force increase on the contrary if this dial is turned CCW counterclockwise then the cutting force decreases This control dial is used to control the cutting pressure applied to the material during the cutting period Proper cutting pressures are supposed to be chosen to achieve the most effective cutting conditions when cutting diff...

Page 43: ... being cut should all be considered when selecting the saw blade to be used 2 Place the saw blade onto both the drive and driven wheels using the following procedures 1 Turn the circuit breaker ON 2 Turn the auto manual select switch to 3 Depress the blade up button and raise the saw head until the right insert holder completely clears the front fixed vise 4 Turn the tension handle to position to ...

Page 44: ...n engage the blade holder with the blade to prevent its dislocation from the drive wheel NOTE The blade holder will disengage as the saw blade begins rotating 12 Ensure that the back edge of the saw blade makes contact with the flange of the driven wheel Turn the tension handle to position so that sufficient tension is placed on the saw blade Proper blade tension is obtained NOTE Ensure that the b...

Page 45: ...r WARNING DO NOT shovel chip while the saw band is running Ï Wire Brush Proper Improper 5 Tighten the lock lever and blade cover 4 Close the covers of both the drive wheel and the driven wheel 5 Properly position the blade guide according to the diameter or the width of the workpiece using the following procedures 1 Turn the left insert knob CCW counterclockwise to loosen the left insert 2 Loosen ...

Page 46: ...t with the nuts 6 When performing the single cutting remove the multi vises using the following procedures 1 Disconnect the multi vise hoses 2 Loosen the lock nuts and remove the multi vise 3 Remove the stud bolts Lock Nut Stud Bolt 7 Properly place the workpiece on the work feed table using the following procedures 1 Depress the raise button to raise the saw blade until it is at the highest posit...

Page 47: ... vise so that it pushes against the workpiece Then engage the pawl with the rack 3 Turn the vise clamp selectswitch to and depress No 12 button again so that the workpiece is securely clamped with the rear vise 4 Push the vertical roller guides against the workpiece and lock the guides by tightening the lock handles 5 Turn the rear vise forward backward No 15 button Ð and depress it until the rear...

Page 48: ...hrough 11 omitting step 10 12 After properly adjusting the position of the workpiece to and No 12 button so that the workpiece is securely clamped with the front vise 9 Adjust the saw blade speed 1 Set the flow control at zero 2 Depress the blade drive button to start the saw blade As the blade begins to rotate the rear vise will automatically move to the backward limit position and clamp the work...

Page 49: ...ose nozzle into the wire brush case To determine the value to be set on the cutting length preset counter be sure to use the following equation l t n 1 C n where C Value set on counter mm l Required cutting length mm t Set with 1 6 mm n Feeding times Example When the required cutting length is 600 mm 600 1 6 x 2 1 C 2 299 2 mm Bundle Cutting To perform bundle cutting use the multi vise and proceed...

Page 50: ...t 50 to 150 mm 1 9 5 9 in Proper and improper stacking of workpieces Proper Improper 4 Align the multi vise cylinders with the center of the workpiece to be bundle cut and tighten the lock nuts 5 Turn the multi vise handles so that the clearance between the work retaining plate of the multi vise and the top of the bundled work piece is 5 10 mm 0 2 0 4 in Refer to picture of bundle cutting Page 50 ...

Page 51: ...al wiring 5 After saw head ascends please take off quick approach 6 Remove the rust prevention grease with cleaning oil or kerosene 7 Fixed already for blade tension and steel tungsten leaf 8 Supply coolant 9 Test vise clamp saw head ascending and descending feed vise bed forward and backward using manual operation Unloading test 1 First you have to clamp the workpieces with rear vise clamp 2 Retu...

Page 52: ... operation if you practice a couple of hours 4 5 HOW TO REPLACE THE SAW BLADE Unfolding saw blade When you decide to unfold saw blade in order to change a new one you can follow the method as illustrated below CAUTION Please wear leather gloves and protective goggles in those procedures You can refer Section 4 2 2 manual model to operation Installing saw blade Please refer to 4 3 2 for saw blade c...

Page 53: ...sert open close levers 13 Close the saw blade safety cover and gently close the wheel cover 14 Press the blade drive button to start the saw blade running 15 Open the wheel cover and check to see that the saw blade is not off the drive and driven wheels and is securely pressed against the backup rollers backup tips 16 Move chip of wire brush back to cleaning position Adjust brush allowing the tips...

Page 54: ...llers close to the work by hand and tighten the lock lever of each vertical roller 4 7 PROCEDURES TO STOP AN OPERATING PROCESS STOP Manual cutting operating To stop the cutting operation please press the BLADE UP button or HYDRAULIC OFF button The saw blade stops running when the BLADE UP button is pressed The saw blade and hydraulic pump motor both stop running when the HYDRAULIC OFF button is pr...

Page 55: ...ing after removing the cause for the stop When the AUTO MANUAL selectswitch is turned to MANUAL while the machine is operating in the automatic mode the saw blade stops running When the AUTO MANUAL selectswitch is turned to MANUAL while the saw blade is cutting the work the saw blade stops running after completing the cut The operation that was stopped by turning the AUTO MANUAL selectswitch to MA...

Page 56: ...Section 5 ELECTRICAL SYSTEM Page 56 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 57: ...the electric cabinet will be described in section 5 2 The circuit symbol explanation and the circuit diagram will be described in section 5 2 5 2 ELECTRICAL COMPONENTS LAYOUT The electrical components on the whole machine is shown in Figure 5 1 The locations of limit switches sensors control panel and electric cabinet are indicated in the figure They provide a global view of the electrical system ...

Page 58: ...The electric circuit diagrams shown here are The electric circuit diagram of the system The PLC drawings T2 and input module A1 the PLC input module A2 The PLC input module A3 and A4 The PLC input module A5 and A6 They are designated as technical construction file Page 58 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 59: ...ELECTRICAL SYSTEM Section 5 5 3 Fig 5 2 PANEAL DIAGRAM Page 59 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 60: ...ELECTRICAL SYSTEM Section 5 5 4 Fig 5 3 ELECTRICAL BOX LAYOUT DIAGRAM Page 60 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 61: ...ELECTRICAL SYSTEM Section 5 5 5 Fig 5 4 POWER SUPPLY DIAGRAM Page 61 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 62: ...ELECTRICAL SYSTEM Section 5 5 6 Fig 5 5 PLC I O DIAGRAM Page 62 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 63: ... REAR VISE BACKWARD X08 MANUAL AUTO SELECT Y08 REAR VISE FORWARD X09 FRONT REAR VISES SELECT Y09 REAR VISE CLAMP X10 LOWER LIMIT SWITCH Y10 FRONT VISE CLAMP X11 UPPER LIMIT SWITCH Y11 QUICK APPROACH X12 BACKWARD LIMIT SWITCH X13 FORWARD LIMIT SWITCH X14 COUNTER OUTPUT X15 NO WORKPIECE X16 THERMAL OVERLOAD X17 SAW BLADE MOTION DETECTOR X18 COUNTER ON OFF X19 SINGLE BUNDEL SELECT X20 COOLANT PUMP X2...

Page 64: ...ultaneously 5 4 2 OPERATION This selector switch has manual and automatic settings When set at manual it allows complete operator control of all sawing functions automatic cycle functions are disabled If set at automatic the machine controls indexing and cutting procedures Page 64 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 65: ...ELECTRICAL SYSTEM Section 5 5 9 Fig 5 6 PANEAL DIAGRAM CE Page 65 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 66: ...ELECTRICAL SYSTEM Section 5 5 10 Fig 5 7 ELECTRICAL BOX LAYOUT DIAGRAM CE Page 66 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 67: ...ELECTRICAL SYSTEM Section 5 5 11 Fig 5 8 POWER SUPPLY DIAGRAM CE Page 67 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 68: ...ELECTRICAL SYSTEM Section 5 5 12 Fig 5 9 PLC I O DIAGRAM CE Page 68 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 69: ...Section 6 HYDRAULIC SYSTEM Page 69 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 70: ...es back and forth on the rear material support frame The clamping of the workpiece is also done by the power of two hydraulic cylinders Even for the multi vise used in the occasion of bundle cutting there are small hydraulic cylinders built inside CAUTION During installation or other handing of Teflon hoses do not bend hose to smaller than specified minimum bend radius Installed Teflon hoses remov...

Page 71: ...ram All the parts specification are listed in section 10 part II The layouts of all the hydraulic system elements are shown in figure 6 3 Where figure 6 1 is the global view of the hydraulic system and figure 6 2 shows the source of the hydraulic power ie the hydraulic pump the motor and the hydraulic manifold The list in section 10 part II shows all the elements in figure 6 2 Fig 6 2 THE LAYOUT O...

Page 72: ...HYDRAULIC SYSTEM Section 6 6 3 Fig 6 3 THE LAYOUT OF THE HYDRAULIC SYSTEM Page 72 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 73: ...Section 7 Section 7 BAND SAW CUTTING A PRACTICAL GUIDE Page 73 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 74: ...securely and accurately throughout the sawing process The tension of the saw blade is adjusted through the tensioning device on the strong saw bow The cutting feed and down feed pressure of the blade is regulated automatically by hydraulic regulation 7 2 BAND SAW BLADE SELECTION The factors affecting cutting performance are Type of material Material size and shape Guide spacing Blade selection Bla...

Page 75: ...imited by vibration and the ability to keep the blade sufficiently cool to avoid dulling the teeth A blade which is running fast and taking a very light cut will dull quickly because the tips of the teeth will overheat from the rubbing action If however we force the blade teeth deeper into the material the blade will be less sensitive to heat because the teeth are cutting more and rubbing less Bla...

Page 76: ...ssed below Since the blade sees only that material it is cutting the shape of the stock being cut will also affect cutting speeds particularly if the piece is excessively wide or if it varies in the dimensions being cut Guide Spacing The rigidity of the blade is a function of guide spacing with rigidity being reduced to the third power as the distance between the guides increases For example with ...

Page 77: ...hree teeth in contact with the material being cut 7 3 2 Material Size and Saw Pitch Anytime during the cutting operation at least three teeth must be in contact with the material being cut Figure 7 4 shows some sawing practices Fig 7 4 Some sawing practices Solid Stock Page 77 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 78: ...100 250mm 4 10 3 4 TPI Structurals up to 10 mm 3 8 10 8 TPI 10 20mm 3 8 3 4 8 10 TPI above 20mm 3 4 6 8 TPI Solid up to 20mm 3 4 8 10 TPI 20 80mm 3 4 3 1 4 2 8 TPI above 80 mm 3 1 4 4 6 TPI You can refer to the feed and speed chart Metric Table as follows Page 78 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 79: ...Section 8 MAINTENANCE SERVICE Page 79 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 80: ...ncludes three periods 1 Daily maintenance 2 Monthly maintenance 3 Six months maintenance Before beginning of work each day 9 1 Please check the hydraulic oil level If oil level volume below 1 2 please adding oil as necessary Filling up to 1 3 level is better for system operation 9 2 Please check the cutting fluid level adding fluid as necessary If the fluid appears contaminated or deteriorated dra...

Page 81: ...r working inspection 9 2 Lubricate the following points Front vise slide plates Rear vise slide plates Feed cylinder guide shafts Rear vise guide bars Every monthly maintenance Please apply grease to the following points 9 1 Idle wheel 9 2 Driven wheel 9 3 Blade tension device 9 4 Worm shaft Recommended Grease Shell Alvania EP Grease 2 Mobil Mobilplex 48 1 3 2 4 Page 81 Instruction Manual for AH 2...

Page 82: ...urs of operation whichever occurs first check the sight gauge to ascertain the transmission oil level Lubricant oil must have a viscosity sufficient to reduce friction of the worm and worm gear So that the gear reducer can operate smoothly under high load and impact Recommended Oil SHELL Omala Oil 220 Cold area use eg Korea Russia Mobil Gear 630 Sight Gauge 9 3 Replace the hydraulic oil Recommende...

Page 83: ...6 OIL RECOMMENDATION FOR MAINTENANCE Item Method Revolution Suggest oil Dovetail guide Keep grease covered Antirust Daily Shell R2 Roller bearing Sweep clean and oil with lubricant Daily SEA 10 Bed roller surface Sweep clean and oil with lubricant Daily SEA 10 Nipples of bearing Use grease gun but not excess Monthly Shell R2 Blade tension device Use grease gun but not excess Monthly Shell R2 Reduc...

Page 84: ...Page 84 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 85: ...Section 9 SYSTEM TROUBLE SHOOTING Page 85 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 86: ...tions due to the limited life span of mechanical electric or hydraulic parts of the machine As a twenty year old company COSEN has accumulated enough experiences and technical data to handle all of the regular system troubles Meanwhile the engineering department of COSEN had been continuously improving the machines to prevent all possible troubles It is hoped that you will give COSEN your maintena...

Page 87: ...sted properly Refer to Adjustments Cannot make square cut Rear vise jaw not adjusted properly Set fixed vise jaw 90 to blade Excessive head pressure Reduce head pressure Refer to operating instructions Adjusting Feed Dull blade Replace blade Increased cutting time Insufficient head pressure Increase head pressure Refer to Operating Instructions Adjusting Feed Reduce blade speed Refer to Operating ...

Page 88: ...motor terminals Power line overloaded with lights appliances and other motors Reduce the load on the power line Undersize wires or circuit too long Increase wire sizes or reduce length of wiring General overloading of power company s facilities Request a voltage check from the power company Motor overloaded Reduce load on motor Motor overheat Air circulation through the motor restricted Clean out ...

Page 89: ...ls out of line Adjust wheels Guides out of line For a straight and true cut realign guides check bearings for wear Run out and Run in Excessive pressure Conservative pressure assures long blade life and clean straight cuts Support of blade insufficient Move saw guides as close to work as possible Material not properly secured in vise Clamp material in vise level and securely Blade tension improper...

Page 90: ...rial surface Soften material surface 9 9 9 Excessive cutting rate Reduce cutting rate 9 9 Non annealed workpiece Replace with suitable workpiece 9 9 9 9 Insufficient or lean cutting fluid Add fluid or replace 9 9 9 9 Vibration near machine Relocate machine 9 9 Non water soluble cutting fluid used Replace 9 9 9 Air in cylinder Bleed air 9 9 9 Broken back up roller Replace 9 9 9 9 9 Use of non speci...

Page 91: ...w blade motor is in operation Depress BLADE UP button 4 Vise does not open or close even th ough vise clamp selectswitch is manipulated For problem not indicated on the above chart please refer to the electrical circuit and hydraulic circuit diagrams provided on section 4 5 of this manual 9 8 THE ADJUSTMENT OF THE FEEDING TABLE If the feeding table suffers the huge stroke and the alignment is effe...

Page 92: ...ion 9 9 7 If the feeding table and the machine frame are not positioned under the horizontal balance the loaded material may be going up gradually and affect the cutting effect Page 92 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 93: ...Section 10 PART LIST Page 93 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 94: ...PART LIST Section 10 10 2 Fig 1 BAND SAW FOUNDATION ASSY Page 94 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 95: ...ter hexagon bolt 外六角螺栓 M14 x 20L 1 1 20 AHC 2009 Plate 集削板 1 1 21 deldted 1 22 PP 21030 Oil level gauge 油面錶 3 2 1 23 Spring washer 彈簧墊圈 M8 4 1 24 Screw 螺絲 M8 x 20L 4 1 25 deldted 1 26 deldted 1 27 Set taper screw 止付螺絲 M10 x 45L 2 1 28 PP 90857 Oil tank cap 油箱蓋帽 1 1 29 deldted 1 30 AHA 0138 Filter Plate 濾網板 1 1 31 AHA 0136 Coolant pump fixture 冷卻水泵固定板 1 1 32 PP 31081 Coolant pump 冷卻水泵浦 1 8HP 210L 1...

Page 96: ...PART LIST Section 10 10 4 Fig 2 VISE MACHINE BODY ASSY Page 96 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 97: ... 22 AHA 0225A Straight pin threaded socket 插銷 1 2 23 Set taper screw 止付螺絲 M6 x 8L 1 2 24 AHA 0227A Auxiliary plate 輔助板 3 2 25 Straight pin 彈簧銷 ø3 x 16L 2 2 26 AHA 0229 Front fixed vise jaw front 前固定虎鉗前 1 2 27 AHA 0230 Front fixed vise jaw rear 前固定虎鉗後 1 2 28 AHA 0122B Hexagon socket bolt 內六角螺栓 M16 x 16L 4 2 29 AHA 0234A Slide plate front 床面鋼板前 1 2 30 AHA 0234B Slide plate rear 床面鋼板後 1 2 31 Flat...

Page 98: ...PART LIST Section 10 10 6 Fig 3 TRANSMISSION MECHNICAL ASSY Page 98 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 99: ...screw 平頭十字螺絲 M5 x 16L 4 3 18 Inner hexagon bolt 內六角螺栓 M5 x 12L 2 3 19 Nut 螺帽 M5 2 3 20 AHA 0507 Pulley cover bracket 普利蓋托架 1 3 21 deleted 3 22 deleted 3 23 AHA 0510A Motor base plate 馬達平台 1 3 24 Outer hexagon bolt 外六角螺栓 M10 x 32L 1 3 25 Washer 墊片 M10 2 3 26 AHA 0515 Motor platform support shaft 馬達平台支撐軸 1 3 27 Spring washer 彈簧墊片 M12 1 3 28 Nut 螺帽 M12 1 3 29 deleted 3 30 deleted 3 31 Set taper screw...

Page 100: ...PART LIST Section 10 10 8 Fig 4 POWER UNIT ASSY Page 100 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 101: ... washer 彈簧墊片 M10 4 4 12 Inner hexagon bolt 內六角螺栓 M10 x 25L 4 4 13 AHA 0510A Motor platform 馬達平台 1 4 14 AHA 0510A Motor platform support shaft 馬達平台支撐軸 1 4 15 Spring washer 彈簧墊片 M12 1 4 16 Nut 螺帽 M12 1 4 17 AHA 0526 Motor locking shaft 馬達定位軸 1 4 18 Washer 墊片 M10 2 4 19 Spring washer 彈簧墊片 M10 2 4 20 Outer hexagon bolt 外六角螺栓 M10 X30l 1 4 21 Nut 螺帽 M10 1 4 22 AHA 0510B Motor platform bracket 馬達平台托架 2 4...

Page 102: ...PART LIST Section 10 10 10 Fig 5 GUIDE APPROACH ASSY Page 102 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 103: ...xagon screw 平頭內六角螺絲 M6 x 10L 2 5 11 Inner hexagon bolt 內六角螺栓 M5 x 25L 2 5 12 PP 90100 Limit switch 限動開關 Z 15GD55B 1 5 13 AHA 1754 Descending bar cover plate 下降桿座蓋板 1 5 14 deleted 5 15 deleted 5 16 Outer hexagon bolt 外六角螺栓 M6 x 35L 1 5 17 Nut 螺帽 M6 1 5 18 Inner hexagon bolt 內六角螺栓 M6 x 40L 2 5 19 AHA 1756 Limit switch block 線動開關塊座 1 5 20 AHA 0735 Scale plate 尺規 1 5 21 Inner hexagon bolt 內六角螺栓 M6 x 1...

Page 104: ...PART LIST Section 10 10 12 Fig 6 GUIDE BRACKET ASSY Page 104 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 105: ... washer 彈簧墊片 4 6 24 deleted 6 25 Outer hexagon bolt 外六角螺栓 4 6 26 AHA 07259 Handle 把手 1 6 27 AHA 07259 Straight pin 彈簧銷 2 6 28 AHA 07259 Lock bolt 固定螺栓 1 6 29 deleted 6 30 PP 61005 Warning label direction of blade 警告標示鋸帶方向 2 6 31 deleted 6 32 deleted 6 33 AHA 0737 Guide bracket fixture block 鋸臂固定塊 1 6 34 AHA 0741 Right spring plug 右彈簧塞 1 6 35 AHA 0742 Right insert adjust knob 右調整球型把手 1 6 36 AHA 07...

Page 106: ...PART LIST Section 10 10 14 Fig 7 DRIVE WHEEL ASSY Page 106 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 107: ...8L 2 7 22 Outer hexagon bolt 外六角螺栓 M12 x 40L 6 7 23 AHA 0423 Model plate 機型銘牌 1 7 24 deleted 7 25 Outer hexagon bolt 外六角螺栓 M6 x 12L 4 7 26 Spring washer 彈簧墊片 M12 6 7 27 PP 14908 Castle nut 城堡螺帽 AN 08 1 7 28 PP 14958 Locking washer 鎖緊墊圈 AW 08 1 7 29 AHA 0429 Adjust collar 調整環 1 7 30 PP 14693 Roller bearing 滾柱軸承 32208 2 7 31 AHA 0431 Bearing collar 軸承環 1 7 32 Inner hexagon bolt 內六角螺栓 M6 x 10 14 7 33...

Page 108: ...PART LIST Section 10 10 16 Fig 8 REDUCER GEARBOX ASSY Page 108 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 109: ...oller bearing 滾柱軸承 30306D 1 8 16 Snap ring C ring 扣環 C 環 RTE 62 2 8 17 PP 14691 Roller bearing 滾柱軸承 32206 1 8 18 PP 51070 Oil seal 油封 V 38505 1 8 19 AHA 0319 Bearing case 軸承座 1 8 20 AHA 0320 Wire brush pulley 鋼刷普利 1 8 21 Set taper screw 止付螺絲 M5 x 8L 2 8 22 Inner hexagon bolt 內六角螺栓 M8 x 20L 4 8 23 PP 13250 DU bushing 軸套乾式軸承 MB5060 2 8 24 AHA 0324 Teflon washer 鐵氟龍墊圈 3 8 25 AHA 0325 Thrust bearing ...

Page 110: ...PART LIST Section 10 10 18 Fig 9 ELEC HYD CONTROL BOX ASSY Page 110 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 111: ... 1 9 12 AHA 1804R Elec data panel 電氣控制面板 1 9 13 Hexagon socket flat head screw 內六角平頭螺絲 M5 x 6L 8 9 14 AHA 1806 Rotate konb 旋轉旋鈕 2 9 15 AHB 1102 NC Work lamp fixture 工作燈固定座 2 9 16 PP 90602C Work lamp 工作燈固定座 1 9 17 AGB 70345 NC Lamp cover 燈罩 1 9 18 AGB 70346 NC Transparent plate 透明板 1 9 19 Inner hexagon bolt 內六角螺栓 M4 x 12L 8 9 20 Inner hexagon bolt 內六角螺栓 M3 x 10L 2 9 21 AHA 6100 Flow control valve s...

Page 112: ...PART LIST Section 10 10 20 Fig 10 WIRE BRUSH ASSY Page 112 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 113: ...刷調整連桿 1 10 16 Outer hexagon bolt 外六角螺栓 M8 X 35L 1 10 17 AHA 1220 Wire brush cover 鋼刷護蓋 1 10 18 Brush support washer 鋼刷支撐墊圈 5 16 2 10 19 PP 58002 Wire brush 鋼刷 AC 2196 9 1 10 20 Thumb nut 蝶形螺帽 M8 1 10 21 AHA 1225 Brush cover bracket 鋼刷護蓋固定板 1 10 22 Outer hexagon bolt 外六角螺栓 M8 x 15L 2 10 23 Washer 墊片 M8 2 10 24 Outer hexagon bolt 外六角螺栓 M8 x 16L 2 10 25 Nut 螺帽 M8 1 10 26 PP 13025 DU bushing 軸套乾式軸承 M...

Page 114: ...PART LIST Section 10 10 22 Fig 11 HEAD CYCLINDER ASSY Page 114 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 115: ...agon socket head bolt 內六角螺栓 M10 x25 L 4 11 16 AHA 1116 Piston and rod 活塞及連桿 1 11 17 deleted 11 18 O ring O 型環 P 70 1 11 19 AHA 1119 Cyclinder 喞筒筒身 1 11 20 AHA 1120 Tir rod bolt 繫緊桿螺栓 4 11 21 O ring O 型環 G85 1 11 22 AHA 1122 Cyclinder under cap 喞筒上蓋 1 11 23 Spring washer 彈簧墊片 M12 4 11 24 Nut 螺帽 M12 4 11 25 PP 90015 CE Limite switch 限動開關 XCK M110 1 11 26 Hexagon socket head bolt 內六角螺栓 M6 x 12L 1 11 ...

Page 116: ...PART LIST Section 10 10 24 Fig 12 FEED EQUIPMENT ASSY Page 116 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 117: ...板 1 12 16 AHA 1427 Receiving platform 前送料平台 1 12 17 Spring washer 彈簧墊片 M10 6 12 18 AHA 1439A Counter shaft 計數器軸 1 12 19 PP 15010 Universal joint 萬向連結器 ø 12 1 12 20 AHA 1432 Guide shaft bolt 導軸螺桿 1 12 21 AHA 1424 Fence plate right 防護欄板右 1 12 22 AHA 1432A Fence plate left 防護欄板左 1 12 23 M3L 7 20 Fence plate rod bracket 防護欄板桿托架 1 12 24 PP 53010 Star grib 梅花螺栓 M8 x 25L 1 12 25 AHB 1647 Counter bushin...

Page 118: ...PART LIST Section 10 10 26 Fig 13 MAINFOLD TAPPER ASSY Page 118 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 119: ... 8 deleted 13 9 PP 43521 Solenoid valve 電磁閥 3C4 1 13 10 Hexagon socket head bolt 內六角螺栓 M6 x 76L 12 13 11 PP 43125 Check valve 防逆瓣引導式止回閥 2 13 12 PP 43523 Solenoid valve 電磁瓣 3C9 1 13 13 PP 43525 Solenoid valve 電磁瓣 3C2 1 13 14 13 15 13 16 13 17 13 18 13 19 13 20 13 21 13 22 13 23 13 24 13 25 13 26 13 27 13 28 13 29 13 30 13 31 13 32 13 33 13 34 13 35 13 36 13 37 13 38 13 39 13 40 13 41 13 42 13 43 1...

Page 120: ...PART LIST Section 10 10 28 Fig 14 WORK FEED DEVICE Page 120 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 121: ...螺栓軸蓋板 1 14 21 AHA 1649 Fitting plate 定寸擋板 1 14 22 AHA 1640 Stopper bracket 定寸支座 1 14 23 Hexagon bolt 外六角螺栓 M15 x 15L 2 14 24 PP 13041 DU brushing 軸套乾式軸承 MB1410 1 14 25 AHA 1650 Nut 定寸螺帽 1 14 26 Straight pin 定位銷 ø5 x 50L 1 14 27 PP 9002A CE Limit switch 限動開關 XCR J163 1 14 28 Hexagon socket bolt 內六角螺帽 M6 x 12L 2 14 29 Spring washer 彈簧墊片 M6 2 14 30 AHA 1654 Deliver shaft plate 送料軸固定板 1 14 31 Spring ...

Page 122: ...PART LIST Section 10 10 30 Fig 15 FEED VISE ASSY Page 122 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 123: ...t head bolt 內六角螺栓 M8 x 16L 14 15 24 AHA 1524 Deliver plate 送料平台 1 15 25 Hexagon socket head bolt 內六角螺栓 M16x60L M16x40L 2 15 26 Spring washer 彈簧墊片 M16 4 15 27 AHA 1527 Rear fixed vise jaw 後固定虎鉗 1 15 28 Hexagon head bolt 外六角螺栓 M8 x 30L 5 15 29 Nut 螺帽 M8 3 15 30 PP 51146 Dust seal 防塵套 65 x 79 x 8 11 4 15 31 PP 13260 DU brushing 軸套乾式軸承 MB6540 4 15 32 AHA 1533 CE Switch lever 開關連桿 1 15 33 Spring washe...

Page 124: ...PART LIST Section 10 10 32 Fig 16 MULTI VISE ASSY Page 124 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 125: ...ear cap 活塞後蓋 2 16 14 AHA 1917A Piston 活塞 2 16 15 O ring O 型環 P53 2 16 16 AHA 1919 Spring 彈簧 2 16 17 Straight pin 插銷 ø3 x 8L 2 16 18 AHA 1921 Rear multi vise body 後下壓本體 1 16 19 deleted 16 20 AHA 1923 Adjust wheel 調整輪 2 16 21 deleted 16 22 O ring O 型環 G70 1 16 23 AHA 1925 Cyclinder 汽缸 1 16 24 deleted 16 25 Junction 直接頭 1 4 x 1 4 4 16 26 Flexible pipe 軟管 1 4 x700l 500L 1 16 27 PP 21100 Quick junction...

Page 126: ...PART LIST Section 10 10 34 Fig 17 FEED CYCLINDER ASSY Page 126 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 127: ...ring pin 彈簧銷 ø3 x 28L 1 17 10 O ring O 型環 P50A 1 17 11 deleted 17 12 AHA 1620 Cyclinder 汽缸 1 17 13 AHA 1620 Tie rod 繫桿 4 17 14 AHA 1679 Cyclinder rear end 汽缸後蓋 1 17 15 Spring washer 彈簧墊片 M10 4 17 16 Nut 螺帽 M10 4 17 17 PP 51150 Oil seal 油封 UHS 28 1 17 18 Hexagon socket head bolt 內六角螺栓 M12 x 30L 1 17 19 17 20 17 21 17 22 17 23 17 24 17 25 17 26 17 27 17 28 17 29 17 30 17 31 17 32 17 33 17 34 17 35 1...

Page 128: ...PART LIST Section 10 10 36 Fig 18 IDLE WHEEL ASSY Page 128 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 129: ...asher 彈簧墊片 M4 x 8L 4 18 37 AHA 0670A Sensor bracket 感應器底座 1 18 38 AHA 0672 Sensor switch mounting plate 感應器電門固定板 1 18 39 PP 90594 Proximate sensor switch 限動電門 1 18 40 hexagon socket head bolt 內六角螺栓 M3 x 15L 2 18 41 AHA 0452 Fitting plate saw bow 鋸弓定位板 1 18 42 AHA 0631 Fitting bolt 定位螺栓 1 18 43 AHA 0629 dumper spring 緩衝彈簧 1 18 44 AHA 0630 Spring plate 墊圈 1 18 45 hexagon socket head bolt 內六角螺栓 M6 x ...

Page 130: ...PART LIST Section 10 10 38 Fig 19 BLADE TENSION FACILITY ASSY Page 130 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 131: ...HN 3313 Spring 彈簧 1 19 17 AHA 0618A Piston and rod 活塞及導桿 1 19 18 O ring O 型環 P70 1 19 19 AHB 0655 Niddle valve stopper plate 閥針定位板 1 19 20 Cap screw 蓋板螺絲 M6 x 15 1 19 21 AHA 0618B Cylinder front cap 喞筒前蓋 1 19 22 O ring O 型環 P11 1 19 23 AHB 0651 Rotary valve 切換針閥 1 19 24 AHB 0653 Valve lever 切換把手 1 19 25 Set taper screw 止付螺絲 M6 x 10L 1 19 26 AHB 0660 Label 張力鬆緊銘牌 1 19 27 Hexagon bolt 六角螺栓 M10 x 110...

Page 132: ...k Notes 3 How did you decide to buy this machine Recommended by friend Recommended by store personnel Manufacturer reputation Read advertisement in Other 4 What is your level of experience with the subject covered for machine Beginner Intermediate Advanced 5 How long have you been using a machine years months 6 What kind of optional accessories do you plan to buy Check all that apply Additional sa...

Page 133: ...AIL TO COSEN Stamp To COSEN MACHINERY INDUSTRIAL CO LTD Customer Service Department 110 Ching Fu Street Hsin Chu 300 Taiwan R O C Tel 886 3 5332143 cosen ms9 hinet net Page 133 Instruction Manual for AH 250H B040 04 12 2014 ...

Page 134: ...SEN MACHINERY INDUSTRIAL CO LTD 110 CHING FU STREET HSIN CHU TAIWAN R O C TEL 886 3 5332143 5 FAX 886 3 5348324 e mail cosen ms9 hinet net 9MAH 2505 Page 134 Instruction Manual for AH 250H B040 04 12 2014 ...

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