KARMETAL KMT 280 WOS Operation Manual Download Page 5

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Important!

This form must be duly completed and returned to the manufacturer or its authorized dealer
within

two months

after the date of purchase. Failure to do so will void the warranty.

WARRANTY REGISTRATION FORM

Machine Model

: …………………………………………………………

Serial Number

: …………………………………………………………

Invoice Date

: …………………………………………………………

Invoice Number

: …………………………………………………………

Dealer:

…………………………

Customer:

…………………………

Summary of Contents for KMT 280 WOS

Page 1: ...KK47 24 01 2017 00 KMT 280 WOS OPERATION MANUAL ...

Page 2: ...ARKING NOTE This manual is a part of the machine and must accompany it if moved within the company or sold ATTENTION BEFORE USING THE MACHINE PLEASE READ THIS MANUAL CAREFULLY ALL EXPLANATIONS INSTRUCTIONS AND WARNINGS ARE INTENDED TO PROTECT YOU ...

Page 3: ...90 264 276 59 19 Web www karmetal com tr e mail info karmetal com tr Machine type model KMT 280 WOS Automatic PLC Controlled Band Saw Machine Applicable EC Directives Machinery Directive 2006 42 EC Low Voltage Directive LVD 2006 95 EC and Electromagnetic Compatibility EMC Directive 2004 108 EC Applicable Harmonized Standards TS EN ISO 12100 1 2007 TS EN ISO 12100 2 2006 TS EN ISO 13850 2007 TS EN ...

Page 4: ...adequate wiring improper installation all electrical and electronic components all electrical motors etc and due to accidents or any damage caused by transportation flood fire natural disasters theft are not included in this warranty and are strictly the responsibility of the purchaser 4 Any part returned to KARMETAL or its authorized dealer under the terms of this warranty shall be on the basis o...

Page 5: ...ed and returned to the manufacturer or its authorized dealer within two months after the date of purchase Failure to do so will void the warranty WARRANTY REGISTRATION FORM Machine Model Serial Number Invoice Date Invoice Number Dealer Customer ...

Page 6: ...ked Machine 16 2 After Unpacking the Machine 16 3 Environmental Conditions 16 4 Shipping Brace 17 5 Machine Placement and Position 17 CHAPTER IV PREPARATION BEFORE OPERATION 18 1 Cleaning 18 2 Removing the Shipping Brace 18 3 Lubricating 18 4 Hydraulic 18 5 Coolant 18 CHAPTER V OPERATION 20 1 Control Panel 20 2 Touch Panel 21 3 Machine Function System Description 31 CHAPTER VI MAINTENANCE 35 2 WEE...

Page 7: ...o not cut wood and analogous material meat fishery food and agriculture products combustible and radioactive materials Enough space should be provided around the machine to avoid hitting and provide a convenient operation Do not leave any tool on the machine after use Do not put work stock or tools around the machine to avoid injury Do not operate the machine with its safety guards removed Do not ...

Page 8: ...8 2 Danger Zones on the Machine ...

Page 9: ...9 3 Safety Equipments and Assignments ...

Page 10: ...Limit Switch This switch is used to adjust the bow s nadir to goes down Lower limit switch is a factory setting Please do not tinker with the lower limit switch 3 5 Shuttle Vice Rear Limit Switch This switch limits the motion to rear side of shuttle vice When the shuttle vice touch to this switch it stops the movement of shuttle vice 3 6 Shuttle Vice Front Limit Switch This switch limits the motio...

Page 11: ...r 3 9 Vice Switch This switch serves that if there is any loaded material on the machine or not If any material does not touch to this switch PLC displays No material signal 3 10 Emergency Stop Button Emergency stop button places on the operator control panel near the main switch is red button and you can see it easily In emergency cases press to this button to stop the machine Machine does not ru...

Page 12: ...we declared the instructions how to make the electric connection before installing machine or after handling the machine 4 3 High Voltage Label This label shows high voltage risk parts All electrical connections should be done by a qualified electrician 4 4 Safety Equipments Label All the safety devices and guards are designed to intend to protect the operator Please do not remove these safety gua...

Page 13: ... Material Feeding Table with Rolls 1 Bandsaw Blade PLC Control Unit Sensitive Pressure 3 Optional Equipment Bundle Cutting Table Micro Molecular Lubricating System Hydraulic Top Pressure Laser Line Indicator 4 Noise Level In accordence with the Machinery Directive 2006 42 EC The A weighted continous acoustic pressure does not exceed 70 dB A The maximum level of the C weighted instantaneous acousti...

Page 14: ...14 5 Machine Dimensions ...

Page 15: ...e or brown Silver or yellow Silver Silver Silver Silver Silver Band saw speed Decrease Decrease Suitable Increase Suitable Suitable Decrease Suitable Advance speed Decrease Decrease Decrease a little Decrease Suitable Increase Increase Decrease The others Control lubricant coolant level Control lubricant coolant level Control number of teeth Control number of teeth Use thick pitch saw 7 KMT 280 WO...

Page 16: ...achine 2 After Unpacking the Machine Put the machine in a dry and sheltered place to prevent damage to the electrical and mechanical components Apply appropriate lubricant machine oil or grease on the slide ways and non painted areas to prevent rust 3 Environmental Conditions Mains voltage and frequency complying with the machine motor characteristics Environment temperature from 10 C to 50 C Rela...

Page 17: ...ghting The machine and its surroundings should be well lit for operator s safety and for a convenient operation and maintenance Leveling Once the machine has been positioned on the floor it must be leveled Adjust the leveling screws so that the machine is leveled on a horizontal plane in two directions side to side and front to back within a tolerance of 0 1 1000 mm Use vice bed surface to place t...

Page 18: ...be checked A sight gauge is mounted on the machine base to check oil level If the oil level is low add grade 46 hydraulic oil or equivalent up to the indicated point 5 Coolant The machine is shipped with the coolant reservoir empty Fill the reservoir with coolant until it is full A sight gauge is mounted on the machine base to check coolant level Caution Do not run the coolant pump without coolant...

Page 19: ...d rise If the saw frame does not rise change power lead connections by reversing any two of the power leads in the power cord Make sure you repeat steps 2 to 6 of this procedure Final Inspection Checklist before Operation After installing the machine a final inspection should be performed by considering the following checklist Any missing components guards or panels Removal of the shipping brace L...

Page 20: ...he emergency button turn it in the direction indicated on its hub Caution The Emergency stop push button does not disconnect the machine from the main power supply To avoid from serious injury or death due to electricity shock turn the main power switch off or disconnect the machine from the main supply before servicing it Bow Rate Valve The bow rate valve is used to adjust the speed at which the ...

Page 21: ...age is displayed The machine can be operated in two different modes namely Manual Operation and Automatic Operation In Automatic Operation mode the machine functions according to the parameters which are set in the User Settings page Details on how to set the User Settings will be explained later in this section following the explanations on Manual Operation mode Figure 2 ...

Page 22: ... the blade guide arms are opened The amount of coolant flow to the cutting region is adjusted by means of these manually controlled valves Caution Operating the coolant pump without coolant in reservoir may cause damage to the pump 3 Swarf Conveyor Start Stop Swarf conveyor is controlled manually by the keys next to its icon as indicated in Figure 3 4 Shuttle Vice Open This button does not functio...

Page 23: ...16 Reduce Blade Speed 17 Increase Blade Speed 18 Manual 2 3 Automatic Operation Figure 4 In Figure 4 Automatic Operation page is shown On this page operation can be monitored and controlled by using panel keys These functions are described as follows 1 Automatic Operation Start Stop This button is used for starting automatic operation If you press one time cutting progress will start To cancel the...

Page 24: ...ing cutting progress 7 Bow Down This button does not function during cutting progress 8 Workpiece Pull This button does not function during cutting progress 9 Workpiece Forward This button does not function during cutting progress 10 Split Vice Open This button does not function during cutting progress 11 Split Vice Close This button does not function during cutting progress 12 Menu This button is...

Page 25: ...n is prepared Length quantity bundle quantity and blade speed information of workpiece is set After entering all data working line will be automatically saved 50 different works can be saved Operator can select all program or just one line to progress recorded program Figure 5 ...

Page 26: ...26 2 5 User Settings There are 33 system parameters that effects operating You may see parameters below Figure 7 ...

Page 27: ...enance You may find maintenance instructions in this page If these instructions are followed working life of machine will be longer Figure 8 2 8 Time Date Settings System time and date can be updated here Figure 9 ...

Page 28: ...ponent Serial Numbers You may find components that used in machine serial numbers in this page These serial numbers are important as spare parts Also you may see machine total working time in this page Figure 10 ...

Page 29: ...en alarm Saved alarms also appear in lcd screen but they are saved in this page Our service stuff can see alarm times and reasons Figure 11 Instant Alarms Arc Cover is Open Electric Box Cover is Open Replacing the Blade Emergency Stop Blade Rotation Error Lift Arc Saved Alarms Blade Broken Hydraulic Motor Thermal Relay Error Coolant Pump Thermal Relay Error Conveyor Motor Thermal Relay Error Up Do...

Page 30: ...on Alarm No 9 Electric cabinet door open Alarm No 10 Saw head rising time out Alarm No 11 Saw head limit switches fault Alarm No 12 Wheel cover open Alarm No 13 Saw head limits fault Alarm No 14 Saw head position fault Notes Alarm 11 When Up Down Limit switches are active at the same time Alarm 10 This parameter is set in the software If the saw head doesn t complete its upward movement within 10 ...

Page 31: ...ful when moving the adjustable guide arm to prevent hitting the workpiece or vice jaws 3 2 Band Tension System The machine is featured with a hydraulic blade tensioning system A band tension of 40 bar is suitable for the machine under normal conditions The adjusted band tension is automatically applied when the band tension stretch button pressed To loosen the band press blade tension loosen butto...

Page 32: ...o the blade s gullet without extending beyond Caution Switch the main power off before changing the chip brush and wear gloves when changing the brush 4 Blade Changing Procedure In order to achieve accurate and efficient cuts it is important to use a sharp and correct blade for the material being cut 1 Select Manual Operation mode 2 Raise the saw frame to its highest position 3 Press band tension ...

Page 33: ...ion Wear heavy protective work gloves and safety glasses when handling blades to avoid injury 8 Carefully remove the blade from the saw 9 Uncoil the new blade and insert the blade around the band wheels Warning New blades are generally shipped in a coiled form This puts them under tension and can suddenly be uncoiled Take extreme caution to prevent injury when uncoiling the new blade Make sure you...

Page 34: ...retch button to exert sufficient tension on the saw blade 15 Turn off the main switch of the machine 16 Turn the knurled knobs clockwise to tighten the carbide pressure pads against the blade Tighten the carbide guides by hand only Note Do not over tighten the carbide pressure guides 17 Adjust the position of the chip brush so that the bristles reach fully into the gullet of the blade without exte...

Page 35: ...quality condition of the coolant and water boron oil ratio if necessary renew it Non painted parts should be wiped with a clean cloth and oiled with protective machine oil to prevent rust Coolant tank should be cleaned against chips to prevent them accumulating onto the floor of the tank 3 MONTHLY MAINTENANCE Check the level of hydraulic oil from the site gauge If the level drops below indicated m...

Page 36: ...s are loose or set too far apart Premature blade breakage premature tooth wear and chipped tooth Feed rate too high or too low Check your coolant Check adjust carbide blade pressure pads Check wheel alignment Allow enough clearance before starting cut Reduce band tension when the machine isn t operated Cutting speed too high Wrong tooth pitch Incorrect or loose work stock clamping Ineffective cool...

Page 37: ...d coolant 4 Revert the preceding setting procedure for dismantling the machine 5 Separate the material to be disposed of depending on their types and composition and have them collected and or recycled by waste disposal services ORDERING SPARE PARTS When ordering spare parts you must state MACHINE MODEL SERIAL NUMBER PART REFERENCE NUMBER PART NAME Without these references we will not supply the s...

Page 38: ...38 CHAPTER IX SPARE PART LIST ...

Page 39: ...26 15 000 07 Clamp Assembly 1 151 26 06 000 06 Blade Tensioning 1 151 26 11 000 05 Gearbox Assembly 1 151 26 08 000 04 Bow Lift Cylinder Assembly 1 151 23 12 350 03 Bow Assembly 1 151 26 04 000 02 Joint Assembly 1 151 26 03 000 01 Machine Base Assembly 1 151 26 01 000 PART NAME KMT 280 WOS COMPLETE 154 03 180 ...

Page 40: ...40 9 1 MACHINE BASE ASSEMBLY ...

Page 41: ...hine Lift Plate 4 151 42 01 144 22 Manometer 063 0 100 BAR 2 150 04 081 21 Sawdust Cover Sheet bar Connection 2 151 26 01 171 20 Sawdust Cover Plate 1 151 26 01 170 18 Nut M6 6 150 06 392 17 Steel Bolt M6 20 6 150 06 007 16 Washer M6 6 150 06 055 15 Conveyor Motor Connection Plate 1 151 26 23 000 14 Hydraulic Unit Connection Plate 2 151 23 01 155 13 Bolt M6 10 42 150 06 134 12 Board Cover 5 151 04...

Page 42: ...42 9 2 JOINT ASSEMBLY ...

Page 43: ...26 15 Switch 1 150 01 180 14 Bolt M8 20 2 150 06 882 13 Nut M10 2 150 06 317 12 Bolt M10 40 2 150 06 422 11 Bolt M8 20 6 150 06 200 10 Joint Front Cover 1 151 26 03 015 09 Joint Rear Cover 1 151 26 03 014 08 Joint Adjustment Disc 2 151 23 08 013 07 Bearing 33206 ZNL 2 150 06 1158 06 Joint Bearing Protection Cover 2 151 23 08 025 05 Joint shaft 1 151 23 08 024 04 Joint 1 151 23 08 011 03 Bolt M16 4...

Page 44: ...44 9 3 BOW ASSEMBLY ...

Page 45: ...1 150 06 317 20 Steel Bolt M10 48 1 150 06 153 18 Switch 1 150 01 367 17 Lock 2 150 06 890 16 Allen Bolt M8 20 4 150 06 200 15 Knob 2 150 06 1132 07 Allen Bolt M12 35 3 150 06 171 06 Bow Lift Cylinder Connection Plate 1 151 23 04 121 05 Allen Bolt M8 20 1 150 06 200 04 Bolt M8 20 10 150 06 882 03 Allen Bolt M10 25 4 150 06 003 02 Lineer Guide 1 151 26 04 115 01 Bow Frame 1 151 26 04 200 PART NAME ...

Page 46: ...46 9 3 1 BRUSH COMPLETE ...

Page 47: ...ing 4 150 06 1261 09 Hexagonal Bolt 1 150 06 152 08 Wheel 1 150 05 685 07 Hexagonal Bolt 1 150 06 021 06 Brush Connection shim 2 151 23 04 405 05 Plastic Brush 1 151 26 04 433 04 Shaft Ring 2 150 06 800 03 Brush Connection Shaft 1 151 26 04 152 02 Bearing 2 150 06 1247 01 Casting Part 1 151 26 04 151 PART NAME BRUSH COMPLETE NO 151 26 04 150 ...

Page 48: ...48 9 4 BOW LIFT CYLINDER ...

Page 49: ...nder Connection Pin 2 151 09 12 116 10 Nut M14 1 150 06 315 M2 Joint Complete 1 151 09 12 119 09 Felt K09 25 25 33 4 7 1 150 04 093 08 Oil Seal K68 025 1 d25 D29 b9 4 a2 1 150 04 359 07 Cylinder Upper Cover 1 151 04 12 103 06 Cylinder Stopper Pipe 1 151 23 12 313 05 Nut M20 1 5 1 150 06 158 04 Compact Seal K18 063 047 PU 63 47 20 1 150 04 067 03 Cylinder Seal Bushing 1 151 04 12 101 02 O Ring 17 1...

Page 50: ...50 9 4 1 HYDRAULIC UNIT ...

Page 51: ...51 9 4 2 HYDRAULIC DISTRIBUTION CENTER ...

Page 52: ...52 9 5 GEARBOX ASSEMBLY ...

Page 53: ...Bolt M12 60 4 150 06 159 13 Washer M12 4 150 06 247 12 Pulley Adjusting Nut 4 151 09 08 300 11 Steel Bolt M12 40 1 150 06 059 10 Gearbox Shim 1 151 09 08 101 09 Felt D90 d60 b8 1 150 04 874 07 Bearing 3210 BD XL D90 d50 b30 2 150 06 1521 06 Bolt M8 30 8 150 06 042 05 Washer M8 8 150 06 176 04 GearBox Flange 1 151 26 08 001 03 Gearbox Shaft Wedge 2 151 07 08 201 02 Gearbox Shaft 1 150 02 119 01 Gea...

Page 54: ...54 9 6 BLADE TENSIONING ASSEMBLY ...

Page 55: ... 08 Safety Washer M25 1 150 06 534 07 Tensioning Side Blade Wheel Bearing Shim 1 151 09 11 501 06 Bushing 1 151 09 11 510 05 Bearing 6208 2RS d40 d80 b18 2 150 06 1239 04 Tensioning Side Blade Wheel 1 151 09 11 405 03 Allen Bolt M8 25 8 150 06 201 02 Tensioning 2 151 09 11 700 01 Blade Tensioning Complete 1 151 26 11 010 PART NAME Blade Tensioning Assemply 151 26 11 000 ...

Page 56: ...56 9 7 CLAMP ASSEMBLY ...

Page 57: ...g Top Pressure 2 151 23 06 350 07 Side Pressure Pulley 1 151 26 06 425 06 Threaded Rod Protection Cover 1 151 26 06 382 05 Linear Guideway Protection Plate 2 151 26 06 380 04 Guide Rail Protection Cover 1 151 26 06 350 03 Linear Rail 2 150 06 1445 02 Mobile Vice Assembly 1 151 26 06 200 01 Fixed Vice Assembly 1 151 26 06 100 PART NAME Clamp Assembly PART NO 151 26 06 000 ...

Page 58: ...58 9 7 1 FIXED VICE ASSEMBLY ...

Page 59: ... M6 12 150 06 055 19 Front Sheft Lower Plate 1 151 26 06 145 18 Steel Bolt M10 30 4 150 06 040 17 Washer M10 8 150 06 318 16 Vice Front Shelf 1 151 26 06 140 15 Allen Bolt M10 40 2 150 06 422 14 Mobile Jaw Cylinder 1 151 26 06 150 13 Fixed Vice Rear Plate Large 1 151 26 06 128 12 Fixed Vice Rear Plate 1 151 26 06 127 11 Fixed Vice Rear Plate Small 1 151 26 06 126 10 Allen Hb Bolt M6 25 12 150 06 1...

Page 60: ...g Bushing 1 151 09 22 108 10 Mobile Jaw Cylinder Rear Cover 1 151 26 06 155 09 O Ring 3 50 1 150 04 633 08 Nut M16 1 150 06 319 07 Cylinder Seal Bushing 40 50 8 2 150 04 063 06 Cylinder Seal Bushing 1 151 09 22 109 05 O Ring 12 2 1 150 04 094 04 Mobile Jaw Cylinder Shaft 1 151 26 06 154 03 Dust Seal 22 30 4 1 150 04 064 02 Oil Seal 22 32 8 1 150 04 072 01 Seal 22 26 9 4 1 150 04 126 M1 Cylinder Fr...

Page 61: ...61 9 7 1 2 VICE DOUBLE ACTING TOP PRESSURE ...

Page 62: ...d Bolt 2 151 23 06 085 11 Top Pressure Connection Plate 1 151 23 06 356 10 Top Pressure Shim 1 151 23 06 357 09 Top Pressure Adjustment Bolt 1 151 23 06 355 08 Allen Bolt M10 60 4 150 06 53 07 Top Pressure Double Acting Upper Cover 1 151 23 06 354 06 Bedding 35 45 8 2 150 04 661 05 Top Pressure Double Acting Cylinder Frame 1 151 23 06 353 04 O Ring D80 d2 2 150 04 602 03 Seal 55 70 7 5 2 150 04 60...

Page 63: ...63 9 7 2 MOBILE VICE ASSEMBLY ...

Page 64: ... Allen Bolt M12 30 5 150 06 295 21 Short Cylinder Connection Plate 1 151 26 06 260 20 Mobile Vice Fixed Jaw Cylinder 1 151 26 06 250 19 Allen Bolt M10 40 2 150 06 422 18 Mobile Jaw Cylinder 1 151 26 06 150 17 Allen HB Bolt M6 25 18 150 06 1008 16 Jaw Plate 4 151 26 06 125 15 Allen Bolt M12 50 8 150 06 866 14 Washer M12 8 150 06 235 13 Mobile Vice Fixed Jaw Lower Slide 1 151 26 06 233 12 Mobile Vic...

Page 65: ...65 9 7 2 1 MOBILE VICE FIXED JAW ...

Page 66: ...l d25 D29 b9 4 a2 1 150 04 359 08 O Ring 3 20 1 150 04 129 07 Mobile Vice Fixed Jaw Cylinder Front Cover 1 151 26 06 256 06 Allen Bolt M10 30 1 150 06 020 05 Seal 63 50 8 2 150 04 161 04 Mobile Vice Fixed Jaw Cylinder Seal Bushing 1 151 26 06 255 03 O Ring 3 20 1 150 04 129 02 Mobile Vice Fixed Jaw Cylinder Shaft 1 151 26 06 254 01 Mobile Vice Fixed Jaw Cylinder Frame 1 151 26 06 251 PART NAME Mob...

Page 67: ...67 9 7 3 VICE CONNECTION TENSIONING ASSEMBLY ...

Page 68: ...18 15 Motor 1 150 03 045 14 Hexagonal Bolt M8 25 4 150 06 1027 13 Washer M8 4 150 06 173 12 Motor Connection Flange 1 151 26 06 317 11 Bolt M6 15 1 150 06 833 10 Wheel Collet 1 151 23 06 023 09 Timing Belt Pulley 1 151 26 06 316 08 Wedge 1 151 26 06 319 07 Split Adjustment Pin 1 151 23 06 319 06 Threaded Rod 1 151 26 06 315 05 Bearing 32305 2 150 06 1173 04 Bolt M8 35 6 150 06 122 03 Plate Connect...

Page 69: ...69 9 7 3 1 VICE REAR ROLLER GROUP ...

Page 70: ...2 150 06 337 05 Nut M24 1 5 2 150 06 058 04 Roller Adjustment Bolt 2 151 26 06 373 03 Bearing 6304 ZZ KRS 2 150 06 233 02 Vice Rear Roller Shaft 1 151 26 06 372 01 Vice Rear Roller 1 151 26 06 371 PART NAME Vice Rear Roller Group PART NO 151 26 06 370 ...

Page 71: ...71 9 8 BLADE GUIDE ASSEMBLY ...

Page 72: ...ock Adjustment Plate 2 151 15 15 075 09 Blade Guide Block Left 1 151 26 15 030 08 Blade Guide Block Right 1 151 26 15 020 07 Hexagonal Bolt M12 50 1 150 06 462 06 Bakelite Nut 25mm 2 150 06 298 05 Fixing Rod Shaft 1 151 09 15 800 04 Arm Fixing Rod 1 151 23 15 038 03 Washer M10 2 150 06 318 02 Arm Fixing Rod Arm 2 151 09 15 600 01 Blade Guide Arm 2 151 23 15 010 PART NAME Blade Guide Assemply PART ...

Page 73: ...73 9 8 1 RIGHT BLOCK COMPLETE ...

Page 74: ...150 06 253 11 Allen HB Bolt M6 16 2 150 06 120 10 Bearing 6001 2Z 4 150 06 1176 09 Bearing Adjustment Shaft Long 1 151 26 15 025 08 Bearing Adjustment Shaft short 1 151 26 15 024 07 Bolt M6 12 4 150 06 128 06 Allen Bolt M6 15 1 150 06 833 05 Fitting 1 151 09 15 370 04 Washer M6 4 150 06 285 03 Carbide Bolt 1 151 26 15 026 02 Carbide Complete 2 151 09 15 341 01 Right Block 1 151 26 15 021 PART NAME...

Page 75: ...75 9 8 2 LEFT BLOCK COMPLETE ...

Page 76: ... 150 06 253 11 Allen HB Bolt M6 16 2 150 06 120 10 Bearing 6001 2Z 4 150 06 1176 09 Bearing Adjustment Shaft Long 1 151 26 15 025 08 Bearing Adjustment Shaft short 1 151 26 15 024 07 Bolt M6 12 4 150 06 128 06 Allen Bolt M6 15 1 150 06 833 05 Fitting 1 151 09 15 370 04 Washer M6 4 150 06 285 03 Carbide Bolt 1 151 26 15 026 02 Carbide Complete 2 151 09 15 341 01 Right Block 1 151 26 15 021 PART NAM...

Page 77: ...77 9 9 ELECTRIC GROUP ...

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