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Sharp SW-120NC, Инструкция по эксплуатации

Новый Sharp SW-120NC - мощный и надежный угловой болгарский! Необходимо как следует ознакомиться с инструкцией по использованию, чтобы извлечь максимальную отдачу от этого инструмента. Скачайте бесплатно Руководство по эксплуатации с manualshive.com и начните работу!

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8

‐

3

 

 

Every

 

month

 

1.

 

Clean

 

the

 

filter

 

of

 

the

 

oil

 

tank.

 

2.

 

Please

 

apply

 

grease

 

to

 

the

 

blade

 

tension

 

device.

 

Recommended

 

Grease:

 

•

 

Shell

 

Alvania

 

EP

 

Grease

 

2

 

•

 

Mobil

 

Mobilplex

 

48

 

 

Every

 

600

 

hours

 

/

 

every

 

1200

 

hours

 

After

 

600

 

hours

 

of

 

initial

 

operation,

 

drain

 

away

 

the

 

oil

 

and

 

clean

 

the

 

internals

 

of

 

the

 

machine,

 

then

 

refill

 

new

 

oil.

 

Do

 

so

 

hereafter

 

every

 

1200

 

hours

 

of

 

operation.

 

Recommended

 

gear

 

oil:

 

 

Shell

 

Omala

 

oil

 

R220

 

 

Mobil

 

gear

 

630

 

Recommended

 

hydraulic

 

oil:

 

 

Shell

 

Tellus

 

32

 

 

Mobil

 

DTE

 

Oil

 

Light

 

Hydraulic

 

24

 

 

Every

 

six

 

months

 

Clean

 

or

 

change

 

hydraulic

 

circuits

 

and

 

inner

 

filter

 

if

 

there

 

is

 

an

 

oil

 

tank.

 

 

 

STORAGE

 

CONDITIONS

 

 

Generally,

 

this

 

machine

 

will

 

be

 

stored

 

on

 

the

 

following

 

conditions

 

in

 

future:

 

1.

 

Turn

 

off

 

the

 

power.

 

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

 

disposal:

 

When

 

your

 

machine

 

can

 

not

 

work

 

anymore,

 

you

 

should

 

leak

 

out

 

the

 

oil

 

from

 

machine

 

body.

 

Please

 

storage

 

the

 

oil

 

in

 

a

 

safe

 

place.

 

Ask

 

an

 

environment

 

specialist

 

how

 

to

 

handle

 

the

 

oil

 

to

 

avoid

 

soil

 

pollution.

 

The

 

oil

 

in

 

machine:

 

 

 

 

Hydraulic

 

oil

 

 

 

 

Cutting

 

fluid

 

 

 

 

Drive

 

shaft

 

grease

 

oil

 

 

 

Содержание SW-120NC

Страница 1: ...SW 120NC Instruction Manual Version 3 20180105 ...

Страница 2: ......

Страница 3: ...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...

Страница 4: ...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 ...

Страница 5: ...ification 2 3 Floor Plan 2 5 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 3 8 Anchoring the Machine 3 9 Installing Roller Table Optional 3 9 Installing Fire Control Devic...

Страница 6: ...4 26 Cutting Operation 4 27 Starting an Automatic Operation 4 28 Using Top Clamp for Bundle Cutting 4 29 Terminating a Cutting Operation 4 30 Section 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 1 Saw Blade Selection 7 1 Some Sawing Practices 7 4 Saw Pitch Selection 7 4 M...

Страница 7: ... Oil Recommendation for Maintenance 8 4 Section 9 Troubleshooting 9 1 Introduction 9 1 Precautions 9 2 General 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 6 Section 10 Parts 10 1 Spare Parts Recommendations 10 1 Part List 10 2 ...

Страница 8: ......

Страница 9: ...ual you will also see various safety related symbols indicating important information that you should take note of prior to use of the 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 S...

Страница 10: ... a roller table recommended Do not use the machine to cut explosive material or high pressure vessels as it will generate great amount of heat during the sawing process and may ignite an explosion Wear proper apparel during operation and when servicing the machine Some personal protective equipment is required for the safe use of the machine e g protection goggles Never operate while under the inf...

Страница 11: ...er 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 following mai...

Страница 12: ...re 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 econo...

Страница 13: ...1 5 Illustration Emergency Stop Emergency Stop Button ...

Страница 14: ...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 ...

Страница 15: ...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...

Страница 16: ...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...

Страница 17: ...1 9 Illustration Safety Labels SW 120NC ...

Страница 18: ... the 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 Our 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 the...

Страница 19: ...cally 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 d...

Страница 20: ... Hydraulic Guide Interchangeable tungsten carbide Cleaning Steel wire brush with flexible drive shaft driven by main motor Motor Output Saw Blade 5 HP 3 75 kW Hydraulic 1 HP 0 75 kW Coolant Pump 1 8 HP 0 1 kW Tank Capacity Hydraulic 6 6 gal 25 L Coolant 11 9 gal 45 L Feeding Length Mode Hydraulic NC Automatic Single Stroke 15 86 403 mm Workbed Height 26 660 mm Weight Net 3 528 lb 1 600 kg Gross 3 ...

Страница 21: ...2 3 MACHINE PARTS IDENTIFICATION Machine front view Machine side view Gear Reducer Workbed Feed Roller Vertical Alignment Roller Roller Table optional Hydraulic Pump Coolant Pump Cleaning Hose ...

Страница 22: ...2 4 Machine top view Chip Conveyor optional Blade Motor Rear Vise Feed Cylinder Length Setting Stopper Rear Vise Assembly Rear Vise Cylinder Control Panel Discharge Table ...

Страница 23: ...2 5 FLOOR PLAN Machine top view Machine front view ...

Страница 24: ...2 6 Machine side view ...

Страница 25: ...ce and inspection Refer to Section 2 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 Away from vib...

Страница 26: ...hecking the model plate on the machine base It is also imperative that a thorough inspection be undertaken to check for any damage that could have occurred during shipping Pay special 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 ...

Страница 27: ...alified 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 hooks on the four ends of the machine Slowly lift the machine Be sure to protect the machine from impact or shock during this procedure Also watch out your own fingers and feet to avoid injuries Keep the ...

Страница 28: ...orklift operator to perform the job You must apply proper forklift technique to avoid damage to the machine Make sure the forks are able to reach in at least 2 3 of the machine depth You must keep the machine balanced at all times Make sure the forks are centered before use Illustration only Refer to Illustration Lifting Points for exact locations 3 Use rolling cylinders You can use rolling cylind...

Страница 29: ...3 5 Illustration Lifting Points Minimum weight capacity for each wire rope 2 ton Total number of wire ropes required 4 ...

Страница 30: ...ion remove the rust preventive grease with wiping cloth dampened with cleaning oil or kerosene Apply machine oil to machine 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 Our bandsaw machine is relatively easy to install Follow these six easy steps to i...

Страница 31: ... enough coolant supply in the tank the pump and its drive motor may be damaged Refer to specification chart under Section 2 Specification for tank capacity Consult your coolant supplier for bandsaw use regarding coolant type and mix ratio Connecting electric power Have a qualified electrician make the electrical connections If the power supply voltage is different from the transformer and motor co...

Страница 32: ...t 5 Connect the power supply cable to the circuit breaker N F B to the R S and T terminals and connect the ground cable to the E terminal 6 Close the compartment door and fasten the screw back 7 Turn on the shop circuit breaker and then turn the machine circuit breaker switch to ON The Power Indicator on the control panel will come on 8 Pull to unlock the Emergency Stop button and press the hydrau...

Страница 33: ...he machine is likely to vibrate fix the machine to the floor with anchor bolts Shock absorption steel plates are provided and can be placed under each leveling bolt to prevent their sinking into the concrete floor Installing roller table optional The roller table is used to support long material at the rear and or the front of the machine If you have ordered the optional roller table for cutting l...

Страница 34: ... turn off the power 2 Fix the saw frame using the shipping bracket that originally came with the machine 3 If you are shipping the machine pack the machine carefully with industrial plastic wraps to protect it from dust 4 Use a crane or forklift to raise it If a crane is used to lift the machine ensure that the lifting cable is properly attached to the machine 5 Do not forget to include the equipm...

Страница 35: ...NG INSTALLING THE BLADE ADJUSTING WIRE BRUSH ADJUSTING SAW ARM ADJUSTING COOLANT FLOW ADJUSTING BLADE SPEED BREAKING IN THE BLADE PLACING WORKPIECE ONTO WORKBED POSITIONING WORKPIECE FOR CUTTING TEST RUNNING THE MACHINE CUTTING OPERATION STARTING AN AUTOMATIC OPERATION USING TOP CLAMP FOR BUNDLE CUTTING TERMINATING A CUTTING OPERATION ...

Страница 36: ...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...

Страница 37: ...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 ...

Страница 38: ...st fully understand the function of each switch and button before operating the machine No Name No Name 1 Emergency stop button 7 Rear vise open button 2 Power indicator lamp 8 Rear vise clamp button 3 Saw bow down button 9 Feed forward button 4 Saw bow up button 10 Feed backward button 5 Front vise open button 11 Blade speed control knob 6 Front vise clamp button 12 HMI touch screen 2 1 3 4 5 9 1...

Страница 39: ...n is pressed the saw bow rises until the operator lets go of the button or until the saw bow touches the upper limit switch While pressing the saw bow up button can stop the running blade please still make use of the emergency stop button in an emergency 5 Front vise open button This button only works when the machine is switched to manual mode If the saw bow is not above the middle limit switch t...

Страница 40: ...ward button When this button is pressed the feeding workbed will move backward Press and hold the button to feed backward As soon as the button is released the feeding workbed will stop moving backward This button only works when the machine is switched to manual mode This button is only in function when the quick approach bar is touching the upper limit switch AND when either of the front and rea...

Страница 41: ...me and quality cutoff surface Set the blade descend speed in accordance with the cutting pressure control knob Also commonly known as the flow control valve Human Machine Interface HMI Touch Screen This HMI touch screen displays operation messages so that the operator is able to understand the system condition It also provides different operating modes and selections for the operator to work with ...

Страница 42: ...onvenient functions are added to the page for the operator to better understand the features of the machine Setting the parameters shown on the screen requires a gentle touch of the finger You can also look up the parameters or make changes while in the middle of a cut Refer to the table below for descriptions of each function No Item Function Description 1 Hydraulic start When the power is turned...

Страница 43: ...matically operate according to the preset parameters Manual mode used to perform individual cutting job When switched to the Manual mode you can execute each individual function Trim Cut When the machine is switched from the Manual mode to the AUTO mode the first cut trim cut will not be counted into finished cuts and the machine will continue to operate according to the preset parameter This func...

Страница 44: ...s with the AUTO mode When under AUTO mode and before proceeding with your automatic cutting jobs select 0 if you wish the first cut to be trim cut i e trimming the edge of your material without the cut being counted into the finished cuts In the other hand select 1 if you do not need to trim cut the material The first cut will then be counted as the first cut of your programmed jobs After the firs...

Страница 45: ...ates that the quick approach bar is contacting the upper limit switch When quick approach function is activated the saw blade icon will turn solid white 19 Saw blade down indicator Indicates that a cut is completed and the saw blade is at its lowest position When the blade completes each cut and triggers the lower limit switch the saw blade icon will turn solid white 20 Rear vise status indicator ...

Страница 46: ...status display This page shows the following information from top to bottom Feeding length current feeding vise position Blade speed Current in ampere optional Number of current cutting job step in operation Preset quantity of current cutting job Number of cuts finished The green square light on the bottom left corner indicates the warranty status of the HMI touch screen Warranty is one year and s...

Страница 47: ...previous setup page Press Next to go to the next setup page Page 3 cutting program setup In this page you can set your desired cutting length and quantity and see the number of finished cuts Cut Finished A total of 100 cutting jobs can be set and performed under the automatic mode In start job and the end job field fill in the number of the cutting job you wish to start and end with The machine wi...

Страница 48: ...tting programs Step 00 99 Cutting program setup When cutting is in operation press to quickly access the cutting program setup page the same as page 3 of the cutting status display and setup page This setup page is the same as page 3 of the cutting status display and setup page Material cutting reference This reference chart lists out the required blade speed and cutting rate for each different ma...

Страница 49: ...e Press Home to return to the main control menu Press Next to go to the troubleshooting support page Page 2 troubleshooting Provides suggestions on troubleshooting 6 pages in total Also refer to the below table for error codes descriptions and solutions Press Home to return to the main control menu Press Next to go to the troubleshooting support page ...

Страница 50: ...ks M313 OL1 abnormal Check if the blade motor overload relay has tripped M314 OL2 abnormal Check if the hydraulic motor overload relay has tripped M315 OL3 abnormal Check if the coolant pump motor overload relay has tripped M316 Saw bow upper limit abnormal Check the upper limit switch works M352 Front vise clamping error 1 Place new material 2 Check if the vise queen valve works 3 Check if the no...

Страница 51: ... motion detector also functions as a safety device The speed motion detector protects operators and the machine by preventing blade overloads and consequent damages if a saw blade breaks or skids Once blade breakage or slippage is detected the drive wheel will stop in 10 seconds Inverter This inverter is installed under the workbed It is used to control and stabilize the saw blade speed during cut...

Страница 52: ...d gear reducer can work toward your preset blade speed and torque Please refer to Section 8 for information on maintenance OPTIONAL ACCESSORIES Vise pressure regulator This adjustment valve is used to control vise pressure Adjust vise pressure based on the material of your workpiece When cutting pipes or soft materials reduce vise pressure to prevent exerted pressure from damaging the workpiece sh...

Страница 53: ...lar maintenance remove the chip conveyor and clean all chip deposits inside Hydraulic top clamps The top clamp device composed of two clamps is installed on top of the front and rear vises before executing bundle cutting Refer to Using Top Clamp for Bundle Cutting for operating procedure on bundle cutting 2M roller table The optional 2M roller table supports the work material and ensures the mater...

Страница 54: ...ll 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 machine power by switching to ON and turn on the hydraulic system Step 3 Switch to manual mode Step 4 Press the saw bow up button and elevate the saw bow until the right insert holder is clear of the front fixed vise ...

Страница 55: ... brush cover Loosen the lock lever and lower the wire brush Step 10 Take out the blade If necessary clean the carbide inserts before installing a new saw blade Step 11 Place the new blade around the idle wheel and the drive wheel Step 12 Insert the blade into the left and right tungsten carbide inserts The back and the sides of the blade need to be touching the inserts as well as the adjacent roll...

Страница 56: ...Allow the blade to run for a few rotations then press the saw bow up button to elevate the saw bow Open the wheel covers and make sure the blade has not fallen off the drive and idle wheels If the blade has shifted follow the same procedure to reinstall the blade again Step 19 Adjust wire brush to a proper position Refer to Adjusting Wire Brush in this section ADJUSTING WIRE BRUSH Follow these ste...

Страница 57: ...e inserts back by tightening the lock nut ADJUSTING COOLANT FLOW Step 1 Press the saw blade start button to start the saw blade drive motor Step 2 Press the saw bow down button to lower the saw bow Step 3 Use the flow control valve shown below to adjust the amount of fluid flowing to the cutting area Adjust the flow amount if you observe the following changes to the chips generated from cutting If...

Страница 58: ...educe the blade speed to one half of its normal setting Step 2 Lengthen the cutting time to 2 3 times of what is normally required Step 3 The complete break in operation requires cutting on a 645 mm2 25 4 square inches section for 5 times Step 4 After the break in operation is completed set all parameters back to normal settings PLACING WORKPIECE ONTO WORKBED Step 1 Press the saw bow up button and...

Страница 59: ...kward button until the rear vises reach back limit switch 7 Press the rear vise clamp button until the workpiece is securely clamped again front vises open prepare for precision position 8 Simultaneously press the front vise open button and the rear vise clamp button again to make sure the material is clamped confirm cutoff point 9 Press the saw bow down button to lower the saw bow until the quick...

Страница 60: ...1 Disassemble shipping brackets and bolts Step 2 Install roller table optional Step 3 Turn on the relay switch in the control box Step 4 Elevate the saw bow If your coolant pump is in reverse and the machine cannot run please change the electrical phase Step 5 After the saw bow ascends extend the quick approach device Step 6 Remove the rust prevention grease with cleaning oil or kerosene Step 7 St...

Страница 61: ...pened to at least wider than the width of the workpiece Step 3 Position your workpiece Step 4 Clamp the workpiece Step 5 Turn the cutting pressure control knob to adjust cutting pressure according to the material Step 6 Adjust blade descend speed control knob to obtain a suitable blade descend speed for your material Step 7 Start running the blade Before you start cutting check again that there is...

Страница 62: ...sition press the saw blade up button to raise the saw bow until the quick approach bar is approximately 10mm 0 4inch above the workpiece Step 3 Turn the Auto manual switch to manual Step 4 Set your desired cutting length and quantity via the HMI touch screen A total of 100 sets of cutting data can be programmed Step 5 Turn the Auto manual switch to Auto Step 6 Press the saw blade start button and ...

Страница 63: ... the workpiece for bundle cutting Note the allowable clamping width and height Refer to Section 2 General Information Specifications Proper and improper stacking of workpieces Proper Improper Step 4 Align the top clamp cylinders with the center of the workpiece and tighten the lock nuts Step 5 Turn the top clamp handles so that the clearance between the top clamp jaw and the top of the bundled wor...

Страница 64: ...ll top clamp for cutting single material Step 1 Disconnect the top clamp hoses Step 2 Loosen the lock nuts and remove the top clamp Step 3 Remove the stud bolts TERMINATING A CUTTING OPERATION STOP To terminate a cutting operation press either the saw bow up button or the emergency stop button The saw blade will stop running when the saw bow up button is pressed Both the saw blade and hydraulic pu...

Страница 65: ...TRICAL SYSTEM ELECTRICAL CIRCUIT DIAGRAMS The following are electrical circuit diagrams of the system Fig 5 1 Control panel layout Fig 5 2 Circuit board layout Fig 5 3 Power supply layout Fig 5 4 PLC input output layout ...

Страница 66: ...5 2 Fig 5 1 Control panel layout ...

Страница 67: ...5 3 Fig 5 2 Circuit board layout ...

Страница 68: ...5 4 Fig 5 3 Power supply layout ...

Страница 69: ...5 5 Fig 5 4 PLC input output layout ...

Страница 70: ......

Страница 71: ...6 1 Section 6 HYDRAULIC SYSTEM HYDRAULIC DIAGRAMS ...

Страница 72: ...6 2 ...

Страница 73: ...distance 2 tpi for example and variable tooth pitches with different tooth distances within one toothing interval Variable tooth pitches for instance 2 3 tpi can be characterized by two measures 2 tpi stands for the maximum tooth distance and 3 tpi stands 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...

Страница 74: ...or blade damage may result It will be slower to cut tubing than to cut solids because the blade must enter the material twice and because coolant will not follow the blade as well Tough or abrasive materials are much harder to cut than their machinability rating would indicate Tooth spacing is determined by the hardness of the material and its thickness in cross section Tooth set prevents the blad...

Страница 75: ...y secured to avoid damage to the machine or injury to the operator BladeBreak In Completing a proper break in on a new band saw blade will dramatically increase its life 1 Select the proper 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...

Страница 76: ......

Страница 77: ...nce 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 the long life and efficient operation of the machine Most of the bas...

Страница 78: ...nd 3 Please check the saw blade to ensure that it is properly positioned on both the drive and idle wheels 4 Please make sure that the saw blade is properly clamped by the left and right inserts 5 Please check the wire brush for proper contact with 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 when work has been compl...

Страница 79: ... STORAGE CONDITIONS Generally this machine will be stored on the following conditions in future 1 Turn off the power 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 A...

Страница 80: ... then refill new oil Do so hereafter every 1200 hours of operation Regularly Shell Omala oil R220 Mobil gear 630 Hydraulic system if there is an oil tank After 600 hours of initial operation drain away the oil and clean the internals of the machine then refill new oil Do so hereafter every 1200 hours of operation Regularly Shell Tellus 32 Mobil DTE Oil Light Hydraulic 24 Bearing Inserts Oil with l...

Страница 81: ... 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 ...

Страница 82: ...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...

Страница 83: ... 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...

Страница 84: ...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...

Страница 85: ...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...

Страница 86: ...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...

Страница 87: ...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 ...

Страница 88: ...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...

Страница 89: ...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...

Страница 90: ...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...

Страница 91: ... 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...

Страница 92: ...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...

Страница 93: ...IONS The following table lists the common spare parts we suggest you purchase in advance Part Name Part Name Saw blade Coolant tank filter Wire brush Steel plates Carbide inserts Rollers Bearings Belt Hydraulic tank leak proof gasket Duster seal Rubber washer Snap ring Oil seal O ring ...

Страница 94: ...ˀˆ ˡ 3 1 5 7 9 NO PART NO PART NAME QYT 1 Base Assembly Base Assembly 1 3 Fixed bed Fixed bed 1 5 Feeding bed Feeding bed 1 7 Saw bow assembly Saw bow assembly 1 9 Control box Control box 1 10 2 SW 120NC ...

Страница 95: ...pper 1 29 PP 90015 CE Limit switch 1 31 AHC 1108 2CE Limit switch stopper 1 33 AHC 0101N 1 Base side cover 1 35 AHC 0101N 3 Base side cover 3 2 37 AHC 0101N 4 Base side cover 4 1 39 AHC 0108 Base right side rear cover 1 41 AHC 0101N 5 Base side cover 5 1 43 AHA 0136 Coolant pump fixed seat cover 1 45 PP 32081 Pump 1 47 PP 90857 Nut 1 49 AHA 0102 Oil tank cover 1 51 AHA 1605 Bushing cap nut 1 53 C3...

Страница 96: ...ront fixed vise 2 1 7 AHC 0223 NC Front movable vise 1 9 AHC 0234A Bed plate 1 1 11 AHC 0234B Bed plate 2 1 13 AHC 2300 NC Vise cylinder assembly 1 15 AHC 0239D Vise plate 4 17 AHC 1423 CE Left bracket 1 19 AHC 1424 Right bracket 1 21 AHC 1427 CE Bracket 1 23 AHC 1437 Supporter 1 25 AHA 0122A Fixed nut 4 27 AHA 0122B Fixed nut 4 10 4 ...

Страница 97: ...13A Feeding bed plate 1 7 AHC 1513B Feeding bed plate 1 9 AHC 2300 NC Vise cylinder assembly 1 11 AHC 1520A Rear movable vise 1 13 AHC 0239D Vise plate 5 15 AGC 2200 1 Rear fixed cylinder assembly 1 17 AGC 2202T Rear fixed cylinder 1 19 AGC 2209B Vise cover 1 21 AHC 1524Y2 Cover 1 23 PP 13260 Du bushing 4 25 PP 51146 Dust seal 4 10 5 ...

Страница 98: ... 07480 Right guide roller assembly 1 17 AHA 06029 Tensioner sliding plate assemly 1 19 C300H 30300 IDLE WHEEL ASSEMBLY 1 21 AHA 0416B Driving wheel 1 23 PP 18187A Blade 1 25 AHC 0515 Washer 1 27 AHA 0734 Adjusting nut 4 29 AHA 0665 CE Idle wheel cover 1 31 AHA 0419 CE Driving wheel cover 1 33 AHA 12110 1 Wire brush bearing seat assembly 1 35 AGC 3028 Pulley cover 1 37 AHA 0737 Saw arm fixed block ...

Страница 99: ...r belt wheel 1 7 AHR 2027 Pulley cover 1 9 AHC 03040 Gear reducer assembly 1 11 AHA 0514G Gear reducer belt wheel 1 13 AHA 0515 Motor movable shaft 1 15 AHC 0501 2 Pulley cover 1 17 AHC 0501 1 Pulley cover 1 19 AHA 0310 Joint shaft 1 21 AHA 0311 Joint shaft cover 1 23 AHA 0324 Hard Long washer 3 25 AHA 0325 Washer 1 27 PP 13250 Du bushing 2 10 7 ...

Страница 100: ...shaft 1 7 AHA 0702B Left movable insert 1 9 AHA 0701B Left fixed insert 1 11 AHA 0710 Spring 1 13 AHA 0709 Left Spring plug 1 15 PBA 6 20 Bolt 1 17 AHA 0711 Adjusting nut 1 19 PP 14270 Bearing 2 21 AHA 0707B Guiding shaft 1 23 AHA 0707C Guiding shaft 3 1 25 AHA 0708B Washer 1 27 PPA 10 WASHER 1 29 PQA 10 Spring washer 2 31 POA 10 Nut 2 33 PAA 6 8 Set screw 1 10 8 ...

Страница 101: ...0713 1 fixed shaft 1 9 AHA 0704A Clamping seat 1 11 AHA 0744B Right fixed insert 1 13 AHA 0743B Right movable insert 1 15 PBA 6 12 Bolt 1 17 AHA 0710 Spring 1 19 AHA 0741 Right Spring plug 1 21 AHA 0742 Adjusting nut 1 23 PP 14270 Bearing 6200VV 2 25 PQA 10 Spring washer 3 27 AHA 0708B Washer 1 29 POA 10 Nut 2 31 AHA 0707C Guilding shaft 1 33 AHA 0707B Washer 1 10 9 ...

Страница 102: ...AHA 06029 9 7 5 3 1 NO PART NO PART NAME QYT 1 AHA 0612A Preesure plate 1 3 AHA 0608A Tensioner sliding plate 1 5 AHA 0603 Tensioner sliding seat 2 7 PQA 8 Spring washer 6 9 PLA 8 25 Bolt 6 10 10 ...

Страница 103: ... NO PART NO PART NAME QYT 1 AHA 0634B Idle wheel 1 3 AHA 0635 Idle wheel shaft 1 5 AHA 0637 Washer 1 7 PP 14613 Conical roller bearing 2 9 PP 14907 Fixed nut 1 11 PP 14957 Stop collar 1 13 SHA 04140 Idle wheel shaft cover 1 10 11 ...

Страница 104: ... 1220 Wire brush cover 1 9 AHA 1230A Wire brush cover 1 11 AHB 0519 Wire brush shaft 1 13 PP 58002 Wire brush 2 15 PP 15010 Universal joint 2 17 PP 13025 Du Bushing 1215 2 19 AHA 1211 Bearing seat 1 21 AHA 1207 Belt wheel shaft 1 23 PP 14272 Bearing 6201V 2 25 AHA 1202 Belt wheel 1 Wire brush assembly Wire brush assembly 10 12 ...

Страница 105: ...h 1 3 AHA 1755B Quick approach stopper 1 5 AHA 1752 Quick approach fixed seat 1 7 AHA 1754 Quick approach Assembly 1 9 PP 53010 Screw 1 11 AHA 1756 Limit switch seat 1 13 PCA 6 10 Bolt 1 15 PBA 6 40 Bolt 1 17 PQA 6 Spring washer 1 19 PBA 6 12 Bolt 1 21 PBA 6 35 Bolt 1 25 PBA 6 25 Bolt 1 10 13 ...

Страница 106: ... 5 3 9 7 1 NO PART NO PART NAME QYT 1 AHC 0131 CE Control box 1 3 AHA 6100 Flow valve assembly 1 5 AHA 10289 Adjusting valve assembly 1 7 AHA 1806 Flow valve assembly 2 9 AHA 0135 CE Flow valv panel plate 1 10 14 ...

Страница 107: ...NO PART NO PART NAME QYT 1 AHA 1563 Encorder seat 1 3 AHA 1564 Tooth bar seat 1 5 AHA 1565 Spring 1 7 AHA 1561 1 Tooth bar 1 9 AHA 1562 Movable plate 1 11 AHA 1560 Inch wheel 1 13 PP 90492 Encorder 1 15 PP 90492 1 Coupling 1 10 15 ...

Страница 108: ...030 Universal joint 1 7 PP 13065 Du bushing 3 9 AHN 1409C AHA 2022B Spiral and core shaft 1 11 AHB 2029 Spiral shaft bearing seat 1 13 AHB 2023C Driving shaft 1 15 AHB 2020C Driving chain wheel 2 1 17 AHB 2019B Driving chain wheel 2 1 19 AHB 2019C Chain wheel 1 21 AHA 2044 Cover 1 23 AHA 2018A Chain wheel cover 1 25 AHB 2030 Coupling 1 10 16 ...

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