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Bandsaw Specialist

Instruction Manual

Model: MH-1016JA/MH-1018JA

Manual Horizontal Bandsaw

with Variable Step Pulley

Ma nu a l

Cosen Mechatronics Co., Ltd.

KC1016W

KC1016VS/

Содержание MH-1016JA

Страница 1: ...Bandsaw Specialist Instruction Manual Model MH 1016JA MH 1018JA Manual Horizontal Bandsaw with Variable Step Pulley Manual Cosen Mechatronics Co Ltd KC1016W KC1016VS...

Страница 2: ...rform any procedures for MH 1016JA MH 1018JA 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...

Страница 3: ...will provide low cost cutting accuracy for many years if the procedures for installation operation maintenance and troubleshooting are followed However if there are questions please contact our agent...

Страница 4: ...1 INTRODUCTION 3 1 3 2 MOVING THE MACHINE 3 1 3 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 5 3 3 4 Unpacking 3 6 3 3 5 Equi...

Страница 5: ...After ending work each day 7 1 Every monthly maintenance 7 2 First Three Months TRANSMISSION OIL REPLACEMENT 7 2 Every Half Of A Year Maintenance 7 2 7 4 STORAGE CONDITION OF THE MACHINE 7 2 3 7 5 TER...

Страница 6: ...Section 1 SAFETY RULES...

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Страница 15: ...Section 2 GENERAL INFORMATION...

Страница 16: ...nce information etc It is divided into 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...

Страница 17: ...60Hz 23 37 58 93M min 75 121 190 305ft min SIZE L 4W T 3350 27 0 9mm 132 x 1 06 x 0 035 SAW BLADE TENSION Manual SAW BLADE 1 5 KW 2 HP HYDRAULIC 0 25HP 0 1875KW MOTOR OUTPUT COOLANT PUMP 0 1 KW 0 125...

Страница 18: ...2 102 157 256ft min SPEED 60Hz 23 37 58 93M min 75 121 190 305ft min SIZE L 4W T 3505 27 0 9mm 138 x 1 06 x 0 035 SAW BLADE TENSION Manual COOLANT CAPACITY CAPACITY 20L 5 28 gal SAW BLADE 1 5 kW 2 HP...

Страница 19: ...GENERAL INFORMATION Section 2 2 4 2 2 2 Identification of Main Parts Terminology MH 1016JA FIG 2 1 TOP VIEW OF THE MACHINE MH 1016JA FIG 2 2 FRONT VIEW DRAWING MH 1016JA...

Страница 20: ...GENERAL INFORMATION Section 2 2 5 FIG 2 3 THE SIDE VIEW OF THE MACHINE MH 1016JA...

Страница 21: ...GENERAL INFORMATION Section 2 2 6 MH 1018JA FIG 2 1 TOP VIEW OF THE MACHINE MH 1018JA...

Страница 22: ...GENERAL INFORMATION Section 2 2 7 FIG 2 2 FRONT VIEW DRAWING MH 1018JA FIG 2 3 THE SIDE VIEW OF THE MACHINE MH 1018JA...

Страница 23: ...the vulnerability to hearing loss varies between individuals and must be taken into account in specifying an allowable limit for noise exposure A level of 90 dBA is widely accepted as a criterion for...

Страница 24: ...saw wheel cover interlock switches located on the two wheel housings are used to assure that the machine will stop whenever the wheel covers are open This device is to protect users from being cut by...

Страница 25: ...BODY GROUND PLATE 1 GROUND PLATE 2 Transformer DOOR 2 3 GUIDE TO THE MANUAL S E C T I O N 1 2 3 1 0 A P P E N D I X The instruction manual is divided into ten sections Each section contains important...

Страница 26: ...nnex I Essential health and safely requirements relating to the design and construction of machinery This section will review the rules on the document and check the current designs of band saw machin...

Страница 27: ...ore performing any activity on the machine such as replacing the saw band or doing regular maintenance WARNING Some personal protective equipment is required for the safe use of the machine e g protec...

Страница 28: ...T Risk assessment generally takes account of intended use and foreseeable misuse including process control and maintenance requirements We made every effort to avoid any personal injury or equipment d...

Страница 29: ...Section 3 MOVING AND STALLATION...

Страница 30: ...ou follow the 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 A CARRYING 1 Use cra...

Страница 31: ...e when you are lifting up the 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 met...

Страница 32: ...spotted on the designated position remove the rust preventive grease with wiping cloth dampened with cleaning oil or kerosene Apply machine oil to the machine surfaces that are susceptible to rusting...

Страница 33: ...king 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...

Страница 34: ...MOVING AND INSTALLATION Section 3 3 5 FIG 3 1 FLOOR SPACE REQUIRED WITHOUT OPTIONAL TABLE FIG 3 2 FOUNDATION DIAGRAM...

Страница 35: ...by step The major machine function setting up is as follows six major steps are Fixing the machine on the floor Machine leveling Installation of feed roller Cutting fluid supply Hydraulic oil supply...

Страница 36: ...orking NOTE 1 Be sure to ascertain that all leveling bolts evenly support the weight of the machine 2 Use a level gauge to make sure that the platform is flat and even at all angles Insrallation of fe...

Страница 37: ...ground terminal The power supply to your machine should agree with the wiring voltage that is indicated on the label attached to the electrical enclosure z If the power line voltage is changed change...

Страница 38: ...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...

Страница 39: ...Section 4 OPERATION INSTRUCTION...

Страница 40: ...t 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 nev...

Страница 41: ...se 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 prod...

Страница 42: ...in an emergency When the button is pressed it brings the machine to a full stop D Coolant ON OFF When switching to I position the coolant pump will start to operate and coolant will start flowing When...

Страница 43: ...lade or material damage Check Prior to Operation 1 Make sure the blade has been installed properly i e the blade teeth are pointing in the right direction 2 Saw blade should be properly installed on t...

Страница 44: ...rial 62 73 Smallest Large Tool stainless and alloy steel bearing bronze 102 121 Small Medium Cast iron mild steel hard brass bronze 157 190 Medium Small Plastic copper soft brass aluminum other light...

Страница 45: ...also the speed mark indicator showing current speed 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 Variable stepless pulley...

Страница 46: ...re can break the blade or stall the saw Insufficient pressure rapidly dulls the blade The hydraulic cylinder regulates the rate at which the blade is lowered into the material being cut Adjusting the...

Страница 47: ...ways use the vise to clamp the work Never hand hold the work for cutting Clamp material securely by turning the vise hand wheel clockwise Angle Cutting The vise offers the user great flexibility in an...

Страница 48: ...Clamp the workpiece with the movable vise jaw Fig 4 4 5 When repositioning the vise for 90 cutting make sure it is square with an accurate square instrument When cutting irregularly shaped material if...

Страница 49: ...mm clearance between saw blade teeth edge and the top of the material Then measure your desired cutoff length 4 Loosen the fastening bolt Fig 9 3 5 Slide and position the stopper Fig 9 6 so that the...

Страница 50: ...CTION 4 4 11 Unrolling installing the blade Caution Always wear leather gloves and protection glasses when handling a blade Unrolling the blade Please follow the procedures illustrated below Fig 4 3 U...

Страница 51: ...he wheel consecutively following the direction of the teeth 5 Apply tension by turning the blade tension handwheel clockwise Make sure the back of the blade is also pressed against the flange of the w...

Страница 52: ...ed horizontal line Adjust the screw Fig 10 2 until the blade is level 3 Tighten the lock nut Fig 10 3 when leveling is obtained Note If the saw blade top line is not leveled against the bed horizontal...

Страница 53: ...ions A Vibration on saw bow Cause 1 Dull blade or stripped blade Remedy Replace a new saw blade Cause 2 Clearance between saw blade and trust roller Fig 11 1 2 is too large Remedy 1 Loosen the two scr...

Страница 54: ...OPERATING INSTRUCTION SECTION 4 4 15...

Страница 55: ...djust the eccentric bushing with a spanner to make the blade 90 to the bed surface Fig 12 4 After finishing the adjustments tighten the locking screws and make sure the faces of two tungsten carbide b...

Страница 56: ...s been factory adjusted at time of manufacturer Do not try to adjust it unless the machine precision has been seriously impacted by damage to the machine If adjustment is absolutely required follow th...

Страница 57: ...Section 5 ELECTRICAL SYSTEM...

Страница 58: ...hine s electric system diagram in easy understand way 5 2 ELECTRICAL CIRCUIT DIAGRAMS As mentioned earlier at the beginning of the section The electric circuit diagrams shown here are The electric cir...

Страница 59: ...ELECTRICAL SYSTEM Section 5 5 2 Fig 5 1 control panel layout...

Страница 60: ...ELECTRICAL SYSTEM Section 5 5 3 Fig 5 2 circuit board layout...

Страница 61: ...ELECTRICAL SYSTEM Section 5 5 4 Fig 5 3 power supply layout...

Страница 62: ...Section 7 Section 6 BAND SAW CUTTING A PRACTICAL GUIDE...

Страница 63: ...ides then holds the blade 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 f...

Страница 64: ...Blade speed is generally limited 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...

Страница 65: ...this width tooth loading may become excessive and the cutting rate must be reduced Above this width blade control begins to be lost as discussed below Since the blade sees only that material it is cu...

Страница 66: ...rser the saw pitch Always have at least three teeth in contact with the material being cut 6 3 2 Material Size and Saw Pitch Anytime during the cutting operation at least three teeth must be in contac...

Страница 67: ...8 10 TPI Teeth per inch 1 4 6 8 TPI 4 10 3 4 TPI Structurals STYLE up to 10 mm 10 20mm above 20mm 3 8 10 8 TPI 3 8 3 4 8 10 TPI 3 4 6 8 TPI Solid Bundle STYLE up to 20 mm 20 80mm above 80mm 3 4 8 10 T...

Страница 68: ...Section 7 MAINTENANCE SERVICE...

Страница 69: ...months maintenance Before beginning of work each day 1 Please check the hydraulic oil level If oil level volume below 1 2 please adding oil as necessary Filling up to 2 3 level is better for system op...

Страница 70: ...e the transmission oil for every half of a year or 1200 hours Check the sight gauge to ascertain the transmission level Recommended TRANSMISSION OIL Omala oil R220 Mobil comp 632 600WCylinder oil 3 Re...

Страница 71: ...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 B...

Страница 72: ...Section 8 SYSTEM TROUBLE SHOOTING...

Страница 73: ...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 th...

Страница 74: ...lade Guide rollers not adjusted properly Refer to Adjustments Rear vise jaw not adjusted properly Set fixed vise jaw 90 to blade Cannot make square cut Excessive head pressure Reduce head pressure Ref...

Страница 75: ...ircuit breakers in power line Install correct fuses or circuit breakers Power line overloaded with lights appliances and other motors Reduce the load on the power line Undersize wires or circuit too l...

Страница 76: ...ippage on drive wheel while cutting Blade breakage Wheels out of line Adjust wheels Guides out of line For a straight and true cut realign guides check bearings for wear Excessive pressure Conservativ...

Страница 77: ...d workpiece Check and correct 9 9 9 Excessively hard material surface Soften material surface 9 9 9 Excessive cutting rate Reduce cutting rate 9 9 Non annealed workpiece Replace with suitable workpiec...

Страница 78: ...he 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 C...

Страница 79: ...Section 9 PART LIST...

Страница 80: ...MH 1016JA series PART LIST 2013 3 25 18 22 7 13 28 20 23 1 9 3 13 8 10 11 5 2 6 27 16 13 14 15 13 23 23 4 12 19 29 24 17 26 25 22 30 9 1...

Страница 81: ...Base side cover 1 13 PBA 6 10 Hex soc cap screw M6 10L 12 14 PLA 12 40 Hexagon bolt M12 40L 4 15 POA 12 Nut M12 4 16 PP 32051 CE Coolant pump 1 17 9607 0002 Wire rope 1 18 MAE 1031 M12 Pin Cylinder 1...

Страница 82: ...MH 1016JA series PART LIST 2012 12 25 22 19 14 20 4 17 12 7 18 6 21 24 24 26 29 13 33 23 16 26 32 10 24 26 25 24 15 31 22 25 16 3 33 28 9 8 30 11 27 32 5 25 23 2 1 9 3...

Страница 83: ...P 52020 Handwheel 1 15 PP 52030 Handwheel handle 1 16 PP 13170 DU bushing 2 17 MJM 5006B Spring 1 18 MJA 1034 Fixed vise pin 1 19 PQA 10 Spring Washer M10 2 20 PBA 10 35 Hex soc cap screw M10 35L 2 21...

Страница 84: ...40 8 9 21 2 3 33 4 3 5 19 17 11 32 28 18 15 29 25 20 38 35 44 43 41 26 23 31 42 15 30 14 22 1 8 7 10 15 13 24 12 16 36 34 37 46 48 Saw bow assembly 45 50 49 39 35 47 51 2012 12 25 MH 1016JA series PAR...

Страница 85: ...1A Motor 2HP 1 24 PQA 8 Spring Washer M8 1 25 POA 8 Nut M8 1 26 PQA 10 Spring Washer M10 4 27 PBA 10 25 Hex soc cap screw M10 25L 4 28 PQB 030 Spring Washer 3 8 4 29 PLB 030 200 Hexagon bolt 3 8 16UNC...

Страница 86: ...60HZ PP 31045 1 Motor 2HP 3 60HZ 600V 2 5A 4P PART NO PART NAME PART NAME IN CHINESE PART SPEC PP 32051A CE Coolant pump CE CE 1 8HP 3 230 240V 460 480V 0 26 0 18A 180L PP 32051 CE Coolant pump CE CE...

Страница 87: ...32 12 2 33 11 14 12 14 13 34 24 21 20 25 20 18 19 29 19 22 26 30 23 24 27 1 28 17 9 3 7 5 6 8 16 10 4 9 13 31 7 6 34 8 11 2014 1 28 MH 1016JA series PART LIST 9 8...

Страница 88: ...2014 1 28 MH 1016JA series PART LIST 9 9...

Страница 89: ...3 MJA 2022 Guide plate 2 4 SJY 1115 Blade tension adjusting shaft 1 5 SJY 1103 Blade tension adjusting lever 1 6 SJY 1104 Blade tension bracket screw 3 7 PAA 6 10 Set screw M6 10L 1 8 MJA 2024 Collar...

Страница 90: ...MH 1016JA series PART LIST 2014 1 27 6 2 17 18 2 17 16 16 3 4 11 10 19 21 20 8 15 13 12 7 9 15 14 18 23 5 1 22 7 22 9 11...

Страница 91: ...MH 1016JA series PART LIST 2014 1 27 Left Guide Roller Assembly 9 12...

Страница 92: ...2014 1 27 MH 1016JA series PART LIST M916J 31600 10 21 11 21 1 3 19 19 7 4 10 13 13 14 20 16 15 17 18 12 2 9 6 8 5 14 6 2 22 9 13...

Страница 93: ...2014 1 27 MH 1016JA series PART LIST M8 Right Guide Roller Assembly 9 14...

Страница 94: ...MH 1016JA series PART LIST 2013 3 1 21 19 14 18 6 13 12 13 22 12 20 1 15 15 12 9 10 2 16 MJA 1035 Lift cylinder 5 24 8 4 17 7 11 23 3 23 11 7 16 24 9 15...

Страница 95: ...PQA 6 Spring washer M6 4 11 MJA 1086B Spring 2 12 PUJ 010 025 01 Curved Fitting 1 8PT 5 16PE 3 13 PP 91115 Nylon tube 2 14 PP 59010 O Ring O P 5 1 15 PP 59072 O Ring O P 16 2 16 PP 59128 O Ring O P 34...

Страница 96: ...9 17 MH 1016JA...

Страница 97: ...MH 1018JA series PART LIST 2013 3 25 16 26 12 27 25 1 13 6 25 20 3 13 28 29 10 18 9 21 8 4 13 14 15 13 7 23 17 5 19 22 11 21 22 2 30 9 18...

Страница 98: ...12 AJC 7025 Base side cover 1 13 PBA 6 10 Hex soc cap screw M6 10L 12 14 PLA 12 40 Hexagon bolt M12 40L 4 15 POA 12 Nut M12 4 16 PP 32051 CE Coolant pump 1 17 9607 0002 Wire rope 1 18 MAE 1031 M12 Pin...

Страница 99: ...MH 1018JA series PART LIST 2012 12 25 1 33 20 15 14 24 19 22 6 7 21 24 22 18 24 26 29 17 24 26 23 11 25 16 26 5 33 25 25 31 30 2 16 23 8 9 12 28 27 32 10 32 13 3 4 9 20...

Страница 100: ...PP 52020 Handwheel 1 15 PP 52030 Handwheel handle 1 16 PP 13170 DU bushing 2 17 MJM 5006B Spring 1 18 MJA 1034 Fixed vise pin 1 19 PQA 10 Spring Washer M10 2 20 PBA 10 35 Hex soc cap screw M10 35L 2 2...

Страница 101: ...MH 1018JA series PART LIST 47 34 15 44 50 40 39 6 7 21 8 46 9 49 2 3 51 4 3 5 19 17 28 11 32 18 15 29 25 20 37 43 34 42 41 26 38 31 31 23 27 30 14 8 22 7 1 10 15 13 24 12 35 16 36 33 Saw bow assembly...

Страница 102: ...31042 Motor 2HP 1 24 PQA 8 Washer M8 1 25 POA 8 Nut M8 1 26 PQA 10 Spring Washer M10 4 27 PBA 10 25 Hex soc cap screw M10 25L 4 28 PQB 030 Spring Washer 3 8 4 29 PLB 030 200 Hexagon bolt 3 8 16UNC 2 4...

Страница 103: ...60HZ PP 31045 1 Motor 2HP 3 60HZ 600V 2 5A 4P PART NO PART NAME PART NAME IN CHINESE PART SPEC PP 32051A CE Coolant pump CE CE 1 8HP 3 230 240V 460 480V 0 26 0 18A 180L PP 32051 CE Coolant pump CE CE...

Страница 104: ...32 12 2 33 11 14 12 14 13 34 24 21 20 25 20 18 19 29 19 22 26 30 23 24 27 1 28 17 9 3 7 5 6 8 16 10 4 9 13 31 7 6 34 8 11 2014 1 28 MH 1016JA series PART LIST 9 25 8...

Страница 105: ...2014 1 28 MH 1016JA series PART LIST 9 26 8 2250L...

Страница 106: ...MH 1016JA series PART LIST 2014 1 27 6 2 17 18 2 17 16 16 3 4 11 10 19 21 20 8 15 13 12 7 9 15 14 18 23 5 1 22 7 22 9 27 8...

Страница 107: ...MH 1016JA series PART LIST 2014 1 27 Left Guide Roller Assembly 9 28 8...

Страница 108: ...2014 1 27 MH 1016JA series PART LIST M916J 31600 10 21 11 21 1 3 19 19 7 4 10 13 13 14 20 16 15 17 18 12 2 9 6 8 5 14 6 2 22 9 29 8...

Страница 109: ...2014 1 27 MH 1016JA series PART LIST M8 Right Guide Roller Assembly 9 30 8...

Страница 110: ...3 MJA 2022 Guide plate 2 4 SJY 1115 Blade tension adjusting shaft 1 5 SJY 1103 Blade tension adjusting lever 1 6 SJY 1104 Blade tension bracket screw 3 7 PAA 6 10 Set screw M6 10L 1 8 MJA 2024 Collar...

Страница 111: ...MH 1018JA series PART LIST 2013 3 4 19 14 18 21 13 12 13 22 12 20 1 15 15 12 9 10 2 6 5 24 8 4 17 7 11 23 3 23 11 7 16 16 S1018 32500 Lift cylinder 24 9 32...

Страница 112: ...PQA 6 Spring washer M6 4 11 MJA 1086B Spring 2 12 PUJ 010 025 01 Curved Fitting 1 8PT 5 16PE 3 13 PP 91115 Nylon tube 2 14 PP 59010 O Ring O P 5 1 15 PP 59072 O Ring O P 16 2 16 PP 59128 O Ring O P 3...

Страница 113: ...9 34 MH 1018JA...

Страница 114: ...COSEN 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...

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