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5

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1

 

Section

 

5

 

ELECTRICAL 
SYSTEM 

 

ELECTRICAL

 

CIRCUIT

 

DIAGRAMS

 

 

 

Model

 

without

 

safety

 

doors

 

&

 

hydraulic

 

vise

 

P.5

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Power

 

Supply

 

Layout

 

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Circuit

 

Board

 

Layout

 

 

Model

 

with

 

safety

 

doors

 

&

 

without

 

hydraulic

 

vise

 

P.5

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4

  

Power

 

Supply

 

Layout

 

P.5

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5

  

Circuit

 

Board

 

Layout

 

 

Model

 

with

 

hydraulic

 

vise

 

P.5

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6

  

Power

 

Supply

 

Layout

 

P.5

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7

  

Circuit

 

Board

 

Layout

 

P.5

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8

 

Control

 

Panel

 

Layout

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for SH-460M

Page 1: ...COSEN SAWS SH 460M Semi Automatic Miter Cutting Bandsaw Instruction Manual The Pinnacle of Cutting Performance Cosen Mechatronics Co Ltd ...

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Page 3: ... 1 877 SAWING1 fax 1 704 943 1031 web www cosensaws com For China email service cosensaws cn phone 86 152 50127815 web www cosensaws cn Instruction Manual SH 460M Semi Automatic Miter Cutting Bandsaw Ver 5 2018 01 08 2013 by COSEN MECHATRONICS CO LTD No part of this publication may be photocopied or otherwise reproduced without the prior written permission of COSEN Printed in Taiwan FROM THE MANUF...

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Page 5: ...our hands clothing or gloves are caught by the running blade Make sure any use of fire is prohibited in the shop and install a fire extinguisher or other fire control device near the machine when cutting titanium magnesium or any other material that produces flammable chips Never leave the machine unattended when cutting flammable materials Use a water soluble cutting fluid on this machine Oil bas...

Page 6: ...ce has been clamped firmly If the workpiece is not securely clamped it will be forced out of the vise during cutting Take preventive measures when cutting thin or short pieces from the work to keep them from falling It is dangerous if the cut pieces fall Use roller tables at the front and rear sides of the machine when cutting long work It is dangerous if the work piece falls off the machine Turn ...

Page 7: ...Floor Plan 2 4 Section 3 Moving Installation 3 1 Location Environment 3 1 Unpacking Inspecting 3 2 Lifting 3 3 Illustration Lifting Points 3 5 Removing Shipping Bracket 3 6 Cleaning 3 6 Installing 3 6 Supplying Hydraulic Oil 3 6 Supplying Coolant 3 7 Connecting Electric Power 3 7 Leveling Anchoring 3 8 Installing Roller Table Optional 3 9 Installing Fire Control Device 3 9 Relocating 3 9 Section 4...

Page 8: ...ection 5 Electrical System 5 1 Electrical Circuit Diagrams 5 1 Section 6 Hydraulic System 6 1 Hydraulic Diagrams 6 1 Section 7 Bandsaw Cutting A Practical Guide 7 1 Introduction 7 2 Saw Blade Selection 7 2 VISE LOADING 7 3 BladeBreak In 7 4 Section 8 Maintenance Service 8 1 Introduction 8 1 Basic Maintenance 8 1 Maintenance Schedule 8 2 Before Beginning a Day s Work 8 2 After Ending a Day s Work 8...

Page 9: ...neral Troubles Solutions 9 2 Minor Troubles Solutions 9 3 Motor Troubles Solutions 9 3 Blade Troubles Solutions 9 4 Sawing Problems Solutions 9 5 Re Adjusting the Roller Table 9 12 Section 10 Parts 10 1 Spare Parts Recommendations 10 1 Part List 10 2 Section 11 Warranty 11 1 Warranty 11 1 ...

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Page 11: ...he machine or part of its functions These important safety instructions do not cover all possible situations that might occur It is your responsibility to take caution and follow procedures stated in this manual when installing maintaining and operating your machine Cosen will not be liable for damages resulting from improper use SAFETY INSTRUCTIONS What the icons and signs in this user manual mea...

Page 12: ...rate while under the influence of drugs alcohol or medication All users must read it before performing any activity on the machine such as replacing the saw band or doing regular maintenance Some personal protective equipment is required for the safe use of the machine e g protection goggles Keep blade protection cover and wheel covers in place and in working order Use recommended accessories Impr...

Page 13: ...henever the machine is running Do not remove any of these safeguard devices under any circumstances except when servicing the machine Even skilled service technicians should still take cautions 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 are not lost and damaged Take note of the followin...

Page 14: ...o assure that the machine will stop whenever the wheel covers are open This device is to protect users from being cut by the running saw blades Among all these safety switches some of them are used to protect the users and some of them are used to prevent damage to saw blades the workpiece and the machine itself etc We have taken every precaution to prevent injury or damage and to provide safe and...

Page 15: ...1 5 Illustration Emergency Stop Model without hydraulic vise Model with hydraulic vise Emergency Stop Button Emergency Stop Button ...

Page 16: ...jury The arrow indicates direction of the blade WARNING Labels An orange and black WARNING label marks hazards or unsafe practices that can result in severe personal injury or damage to the machine Label Meaning Label Meaning Cutting Hazard KEEP COVER CLOSED while the blade is running Turn power off before opening cover Failure to follow the warning can result in severe injury Cutting Hazard KEEP ...

Page 17: ...ades or adjusting wire brush NOTICE Labels Blue and white NOTICE labels mean unsafe practices that could result in damage to products or property Label Meaning Replace the hydraulic oil every six months or every 1 200 hours of operation Oil specification Shell TELLUS 27 or Mobil DTE OIL LIGHT HYDRAULIC 28 To extend blade life always adjust the location of wire brush so that it is properly touching...

Page 18: ...wear gloves neckties jewelry or loose clothing while operating the machine 3 Always wear eye protection goggles 4 Check blade tension and adjust blade guide before starting to cut 5 Always clamp stock firmly in place before cutting 6 Do not remove jammed or cut off pieces until blade has stopped 7 Keep fingers out of path of blade 8 Blade guards should be in place and used at all times 9 Disconnec...

Page 19: ...1 9 Illustration Safety Labels ...

Page 20: ...he prescribed maintenance schedule Refer to Section 8 2 If maintenance does not seem to solve the problem follow the troubleshooting procedures under Section 9 CE COMPLIANCE Cosen s CE model is designed to satisfy regulations of the Council Directive on the approximation of the laws of the Member States relating to machinery 2006 42 EC Annex I Essential health and safety requirements relating to t...

Page 21: ...tically when the saw blade is broken protecting both the operator and the machine Convenience High Performance The machine is designed in the way that the operation and adjustment can be easily performed The machine will stop automatically when out of stock Dual valve system is designed to achieve optimal cutting performance with the simple setting of feed rate and perspective cutting pressure for...

Page 22: ... 20 71 m min 66 233 fpm Size L x W x T 3 505 x 27 x 0 9 mm 138 x 1 06 x 0 035 Tension Manual Guide Interchangeable tungsten carbide Cleaning Steel wire brush Motor Output Saw Blade 2 HP 1 5 kW Hydraulic 1 4 HP 0 19 kW Coolant Pump 1 8 HP 0 09 kW Tank Capacity Hydraulic 8L 2 08 gal Coolant 40 L 10 4 gal Workbed Height 640 mm 25 2 Weight Net 560 kg 1 232 lb Gross 660 kg 1 452 lb Floor Space L x W x ...

Page 23: ...2 3 MACHINE PARTS IDENTIFICATION Electrical Compartment Slide Plate Idle Wheel Cover Saw Bow Left Guide Arm Base Rotating Pivot Seat Drive Wheel Cover Control Panel Work Bed Right Guide Arm Pulley Cover ...

Page 24: ...2 4 FLOOR PLAN Machine top view Machine side view ...

Page 25: ...2 5 Machine front view ...

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Page 27: ...pection Refer to Section 2 General Information Specification for machine dimensions and floor space Environment Well lighted 500 lumen at minimum Floor kept dry at all times in order to prevent operators from slipping Away from direct exposure to the sunlight Room temperature between 5 C to 40 C Humidity level kept at 30 95 without condensation to avoid dew on electric installation and machine Awa...

Page 28: ...attention to machine surface equipments furnished and the electrical and hydraulic systems for damaged cords hoses and fluid leaks In the event of damage caused during shipping please contact your dealer and consult about filing a damage claim with the carrier Your machine comes in with a set of tools for you to maintain the machine The accessories furnished are as follows 1 Tool box 1 pc 2 Grease...

Page 29: ...chine please consult with the original manufacturer or its qualified agent before hanging the machine Machine lifting is likely to damage the machine if not performed properly Warning You must have a qualified crane operator to perform the job You must use tools and equipment with the proper tensile strength and use proper method when moving your machine Apply the wire rope sling to the lifting ho...

Page 30: ...nated by the original manufacturer If there is any doubt on missing lifting points on your machine please consult with the original manufacturer or its qualified agent before lifting the machine Machine lifting is likely to damage the machine if not performed properly You must have a qualified forklift operator to perform the job You must apply proper forklift technique to avoid damage to the mach...

Page 31: ...onment You must use rolling cylinders made in material of proper compressive strength 4 Other ways to move If the machine does not have or stickers please contact your local agent immediately Illustration Lifting Points Minimum weight capacity for each lifting rod 1 ton Total number of lifting rod required 2 ...

Page 32: ... surfaces that are prone to rust Do not remove the rust preventive grease with a metal scraper and do not wipe the painted surfaces with solvent as doing so would damage surface paint INSTALLING Cosen s bandsaw machine is relatively easy to install Follow these six easy steps to install your machine Supplying hydraulic oil Open the filler cap and fill the hydraulic oil tank to above 2 3 or full le...

Page 33: ...e power supply voltage is different from the transformer and motor connection voltage shown on the label attached to the electrical compartment of the machine contact COSEN or your agent immediately Connect to power supply independently and directly Avoid using the same power supply with electric spark machines such as electric welder Unstable electric tension may affect your machine s electric in...

Page 34: ...e control panel will come on 8 Pull to unlock the Emergency Stop button and press the hydraulic ON button to start the hydraulic motor 9 Make sure the sawing area is clear of any objects Start the blade and check the blade rotation If the electrical connections are made correctly the blade should run in a counterclockwise direction If not shut the hydraulics off turn off the machine as well as the...

Page 35: ...ling bolts Installing Fire Control Device Install a fire extinguisher or any other fire control device in the shop in case a fire breaks out RELOCATING We recommend you follow these procedures when relocating or shipping your machine to other place 1 Descend the saw frame to its lowest position then turn off the power 2 Fix the saw frame using the shipping bracket that originally came with the mac...

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Page 37: ...INSTALLING THE BLADE SELECTING BLADE SPEED ADJUSTING BLADE SPEED ANGLE CUTTING ADJUSTING FEED RATE CUTTING PRESSURE ADJUSTING VISE ADJUSTING WIRE BRUSH ADJUSTING SAW ARM CUTTING IRREGULAR CROSS SECTION ADJUSTING COOLANT FLOW INSTALLING MATERIAL STOP BRACKET ADJUSTING HORIZONTAL STOP SPRING CUSHION ...

Page 38: ...material in place before cutting long workpieces Always make sure the material is clamped firmly in place before starting to cut Do not remove jammed or cut off pieces until the blade has come to a full stop Keep fingers away from the path of the blade Protection devices should be in place at all times For your own safety never remove these devices Disconnect machine from the power source before m...

Page 39: ...he material is flammable Never take your eyes off the machine while in operation Cutting fluid For cooling and lubrication purpose we recommend you use water soluble cutting fluids The following table lists out its pros and cons for your reference Pro Con Have a high cooling effect Not flammable Economical Does not require cleaning of the cut products Remove machine paint Lose its rust protection ...

Page 40: ...lade motor and the built in light will come on Make sure the material is securely clamped by the vise before cutting Press the saw bow up button to stop the running blade 2 Emergency stop button Press this button to stop the machine in an emergency When the button is pressed it brings the machine to a full stop The button locks when pressed In order to unlock it please turn the button clockwise 3 ...

Page 41: ...factor to a good cutting time and quality cutoff surface Also commonly known as the flow control valve Model with hydraulic vise No Control Function No Control Function 1 Vise open clamp switch 6 Saw bow slowly down button N A 2 Coolant pump on off switch 7 Saw bow down button 3 Saw blade start button 8 Emergency stop button 4 Saw blade stop button 9 Power indicator lamp 5 Saw bow up button 10 Bla...

Page 42: ... will automatically go up to the top limit switch position 5 Saw bow up button When this button is pressed the saw bow rises until the operator lets go of the button While pressing the saw bow up button can stop the running blade please still make use of the emergency stop button in an emergency 6 Saw bow slowly down button N A 7 Saw bow down button When this button is pressed the saw bow descends...

Page 43: ... knob counterclockwise increases the blade descend speed UNROLLING INSTALLING THE BLADE Always wear leather gloves and protection glasses when handling a blade Unrolling the blade Please follow the procedures illustrated below Unroll and roll the blade Installing a new blade Step 1 Select the most suitable saw blade for your workpiece considering the size shape and material Step 2 Turn on the mach...

Page 44: ...e wheel and press the back of the blade against the flange of the drive wheel Step 11 Make sure the back of the blade is also pressed against the flange of the idle wheel Step 12 Apply tension by turning the blade tension handle clockwise Make sure you have proper blade tension Proper tension exists when the blade does not slip on the drive wheel when cutting Step 13 Make sure the sides of the bla...

Page 45: ... bronze 164 196 Medium Small Plastic copper soft brass aluminum other light materials 277 330 Large Smallest Some materials due to manufacturing processes such as certain types of cast iron pipe or materials containing certain types of welds cannot be cut on the machine ADJUSTING BLADE SPEED 4 Speed Step Pulley Step 1 Remove pulley cover Step 2 Loosen lock handle Step 3 Position belt in proper gro...

Page 46: ...peed level Refer to the blade speed reference chart posted on the pulley cover to see the actual blade speed in m min or ft min Blade Speed Control Knob Blade Speed Reference Chart Speed Mark Indicator ANGLE CUTTING The swivel sawhead allows the user to cut at any angle between 0 straight cut and 60 miter cut The angles have been accurately configured before machine shipment For your miter cutting...

Page 47: ...ulates the rate at which the blade is lowered into the material being cut Adjusting the blade descend speed control knob provides an infinite choice for feed rate When cutting workpiece of 2 mm thick or below please adjust the blade descend speed control knob to between 1 2 gradually when cutting workpiece of 3 mm and above to 3 4 gradually The by pass valve 2 has been factory adjusted and should ...

Page 48: ...de guide arm position based on the size of your workpiece Step 1 Loosen the blade guide locking handle Then adjust the guide arm to a position suitable for your workpiece size Step 2 After adjustment is made tighten the blade guide locking handle CUTTING IRREGULAR CROSS SECTION When cutting irregularly shaped material if possible avoid positioning the work in the way that the cut would be started ...

Page 49: ...g 9 2 and tighten the set screw Fig 9 1 The depth bar is taken off from the machine base during transit for safety reason Step 2 Lift the saw bow and clamp material securely with vise Step 3 Lower the saw bow to allow about 1 mm clearance between saw blade teeth edge and the top of the material Then measure your desired cutoff length Step 4 Loosen the fastening bolt Fig 9 3 Step 5 Slide and positi...

Page 50: ...bed horizontal line Adjust the screw Fig 10 2 until the blade is level Step 3 Tighten the lock nut Fig 10 3 when leveling is obtained If the saw blade top line is not leveled against the bed horizontal line the workpiece will not be able to cut off completely Automatic Shut Off Adjusting Horizontal Stop Spring Cushion The motor should shut off immediately after the blade has cut through the materi...

Page 51: ...y doors hydraulic vise P 5 2 Power Supply Layout P 5 3 Circuit Board Layout Model with safety doors without hydraulic vise P 5 4 Power Supply Layout P 5 5 Circuit Board Layout Model with hydraulic vise P 5 6 Power Supply Layout P 5 7 Circuit Board Layout P 5 8 Control Panel Layout ...

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Page 59: ...6 1 Section 6 HYDRAULIC SYSTEM HYDRAULIC DIAGRAMS ...

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Page 61: ...7 1 Section 7 BANDSAW CUTTING A PRACTICAL GUIDE INTRODUCTION SAW BLADE SELECTION VISE LOADING BladeBreak In SOLUTIONS TO SAWING PROBLEMS ...

Page 62: ...nds for the minimum tooth distance in the toothing interval Constant Variable Min Max 4 Set The bending of teeth to right or left to allow clearance of the back of the blade through the cut 5 Width The nominal dimension of a saw blade as measured from the tip of the tooth to the back of the band 6 Thickness The dimension from side to side on the blade 7 Gullet The curved area at the base of the to...

Page 63: ...blade from binding in the cut It may be either a regular set also called a raker set or a wavy set The regular or raker set is most common and consists of a pattern of one tooth to the left one tooth to the right and one which is straight or unset This type of set is generally used where the material to be cut is uniform in size and for contour cutting Wavy set has groups of teeth set alternately ...

Page 64: ...band speed for the material to be cut 2 Reduce the feed force rate to achieve a cutting rate 20 to 50 of normal soft materials require a larger feed rate reduction than harder materials 3 Begin the first cut at the reduced rate Make sure the teeth are forming a chip Small adjustments to the band speed may be made in the event of excessive noise vibration During the first cut increase feed rate for...

Page 65: ... best performance and longer life of the band saw machine a maintenance schedule is necessary Some of the daily maintenance usually takes just a little time but will give remarkable results for the efficient and proper operation of cutting BASIC MAINTENANCE It is always easy and takes just a little effort to do the basic maintenance But it always turns out to be a very essential process to assure ...

Page 66: ...the saw blade Replace the wire brush if it is worn out After ending a day s work Please remove saw chips and clean the machine with discharging the cutting fluid when work has been completed Do not discharge cutting fluid while the saw blade is operating because it will cause severe injury on operator s hand Be sure the saw blade is fully stop it will be performed after working inspection Every 2 ...

Page 67: ...wer 2 Ambient temperature 5 40 3 Relative humidity 30 95 without condensation 4 Atmosphere use a plastic canvas to cover machine to avoid excessive dust acid fume corrosive gases and salt 5 Avoid exposing to direct sunlight or heat rays which can change the environmental temperature 6 Avoid exposing to abnormal vibration 7 Must be connected to earth TERMINATING THE USE OF THE MACHINE Waste disposa...

Page 68: ...e oil of 600 hours of using Change it every year Regularly Omala oil HD220 Mobil Gear 630 Hydraulic system Inspect half a year Change oil every year Regularly Shell Tellus 32 Mobil DTE oil Light Hydraulic 24 Bearing Inserts Oil with lubricant but not excess Daily Shell R2 Band wheel Oil with lubricant but not excess Weekly Cylinder Oil with lubricant but not excess 6 Monthly Wire brush Oil with lu...

Page 69: ... disable the machine from operating Generally speaking the system troubles in this machine model can be classified into three types namely GENERAL TROUBLES MOTOR TROUBLES and BLADE TROUBLES Although you may have other troubles which can not be recognized in advance such as malfunctions due to the limited life span of mechanical electric or hydraulic parts of the machine We have accumulated enough ...

Page 70: ...er to Operating Instructions Adjusting Feed Excessive blade speed Refer to Operating Instructions Speed Selection Improper blade selection Refer to Operating Instructions Blade Selection Cannot make square cut Dull blade Replace blade Guide rollers not adjusted properly Refer to Adjustments Rear vise jaw not adjusted properly Set fixed vise jaw 90 to blade Excessive head pressure Reduce head press...

Page 71: ... Install correct fuses or circuit breakers Motor fail to develop full power Power output of motor decreases rapidly with decrease in voltage at 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 v...

Page 72: ...n drive wheel while cutting Wheels out of line Adjust wheels Blade line Run out or Run in Guides out of line For a straight and true cut realign guides check bearings for wear 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...

Page 73: ...lamped workpiece Check and correct Excessively hard material surface Soften material surface Excessive cutting rate Reduce cutting rate Non annealed workpiece Replace with suitable workpiece Insufficient or lean cutting fluid Add fluid or replace Vibration near machine Relocate machine Non water soluble cutting fluid used Replace Air in cylinder Bleed air Broken back up roller Replace Use of non s...

Page 74: ...h Material 18 Used Band Is Long On The Tooth Edge 9 Discolored Tips Of Teeth Due To Excessive Frictional Heat 19 Used Band Is Short On The Tooth Edge 10 Heavy Wear On Both Sides Of Band 20 Broken Band Shows A Twist In Band Length 1 Heavy Even Wear On Tips and Corners Of Teeth Probable Cause A Improper break in procedure B Excessive band speed for the type of material being cut This generates a hig...

Page 75: ...eless wheel B Loose or improperly positioned side guides C Blade not perpendicular to cut D Blade rubbing against cut surface on return stroke of machine head E The teeth rubbing against a part of machine such as chip brush assembly guards etc 4 Chipped Or Broken Teeth Probable Cause A Improper break in procedure B Improper blade selection for application C Handling damage due to improper opening ...

Page 76: ...y positioned chip brush C Excessive feeding rate or feed pressure D Movement or vibration of material being cut E Improper tooth pitch for cross sectional size of material being cut F Improper positioning of material being cut G Insufficient sawing fluid due to inadequate supply improper ratio and or improper application H Hard spots in material being cut I Band speed too slow for grade of materia...

Page 77: ...y improper ratio and or improper application B Excessive band speed C Improper feeding rate D Band installed backwards 10 Heavy Wear On Both Sides Of Band Probable Cause A Chipped or broken side guides B Side guide adjustment may be too tight C Insufficient flow of sawing fluid through the side guides D Insufficient sawing fluid due to inadequate supply improper ratio and or improper application 1...

Page 78: ...tt weld breaks See Observations 5 15 and 16 14 Heavy Wear In Only The Smallest Gullets Probable Cause A Excessive feeding rate B Too slow of band speed C Using too fine of a tooth pitch for the size of material being cut 15 Body Breaking Fracture Traveling In An Angular Direction Probable Cause A An excessive twist type of stress existed B Guide arms spread to capacity causing excessive twist from...

Page 79: ... or short 19 on tooth edge C Cutting a tight radius 18 Used Band Is Long On The Tooth Edge Probable Cause A Side guides are too tight rubbing near gullets B Excessive preload band riding heavily against back up guides C Worn band wheels causing uneven tension D Excessive feeding rate E Guide arms are spread to maximum capacity F Improper band tracking back edge rubbing heavy on wheel flange 19 Use...

Page 80: ...adjust TOOL measuring Measurement Horizontal balance Procedure 1 Screw or loosen the adjusting bolt to attain the horizontal balance leveling between the roller table and the machine frame 2 Ensure that the machine frame is not struck by the loaded material on the feeding table 3 Check the leveling by the measuring tool 4 After finished the adjusting fix the roller table If the feeding table and t...

Page 81: ...ART LIST SPARE PARTS RECOMMENDATIONS The following table lists the common spare parts we suggest you purchase in advance Part Name Part Name Saw blade Filter Wire brush Steel plates Carbide inserts Rollers Bearings Belt Chain Duster seal Asbestos Washer ...

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Page 93: ...d normally acceptable practices This warranty does not apply if the machine has been altered or modified without our prior written consent In the case of components or units purchased by Seller including work holding devices tool holders motors and controls the warranty shall not exceed that received by Seller from the supplier of such components or units Seller will not assume responsibility for ...

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Page 96: ...Vertical Plate Saws Horizontal Billet Saws NC CNC Band Saws Structural Miter Cutting Saws Automatic Band Saws Visit our website at www cosen com COSEN MECHATRONICS CO LTD ...

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