INSTRUCTION MANUAL
CS-315C
MetalMaster Cold Saw, Includes Stand (240V)
110 x 70mm
S827
Page 1
Instruction Manual for CS-315C (S827)
03/12/2014
Table of Contents
1 SAFETY REGULATIONS
........................
3
1.1 General Safety Advice
.......................
3
1.2 Blade Guard Safety
...........................
3
1.3 Emergencies
.....................................
3
2 MACHINE DIMENSIONS
.........................
3
3 TECHNICAL CHARACTERISTICS
.........
4
3.1
General Characteristics
.....................
4
4 TRANSPORTING THE MACHINE
...........
4
5 GETTING TO KNOW YOUR MACHINE..4
5.
1 Disk Head Assembly
.........................
4
5.2 Machine Base
....................................
5
5.3 Vice
...................................................
5
5.4 Support
Roller ...................................
5
5.5 Stand
.................................................
5
5.6 Coolant Pump
....................................
5
6 GETTING STARTED
...............................
6
6.1 Minimum Requirements for Housing
the Machine
.............................................
6
6.2 Anchoring the Machine
......................
6
6.3 Assembly and Setup
.........................
6
7 RECOMMENDATIONS AND ADVICE
....
9
7.1 General Advise Before Using the
Machine
.................................................10
7.2 Operator Position
............................10
7.3 Deactivating the Machine
................10
7.4 Dismantling......................................10
8 ADJUSTING THE MACHINE
.................11
8.1 Disk Head........................................11
8.2 Adjusting the Mitering Lock Lever
...11
8.3 Changing the Disk...........................11
8.4 Cleaning and Accessing the Coolant
System
..................................................11
9 THE OPERATION CYCLE
.....................12
9.1 Miter Angle
......................................12
9.2 Vise Operation
.................................12
9.3 Loading the Work-piece
..................12
9.4 Setting Cutting Length
.....................13
9.5 Operation Cycle
...............................13
10 ROUTINE AND SPECIAL
MAINTENANCE
........................................14
10.1 Daily Maintenance.........................14
10.2 Weekly Maintenance
.....................14
10.3 Monthly Maintenance
....................14
10.4 Six-Monthly Maintenance
..............14
10.5 Oils
for Lubricating Coolant
...........14
10.6 Oil Disposal
...................................14
10.7 Special Maintenance
.....................14
11 MATERIAL CLASSIFICATION AND
CHOICE OF TOOL
...................................15
11.1 Disk Structure
................................15
11.2 Choosing the Saw Blade
...............15
11.3 Type of Disks ................................16
11.4 Choosing the Tooth Pitch
..............17
11.5 Cutting and Advance Speed
.........17
11.6 Running in the Disk
.......................18
11.7 Cutting Speed Chart
......................18
11.8 Recommended Cutting Parameters
..............................................................19
12 EXPLOSION DRAW AND PART LISTS
..................................................................20
12.1 Explosion draw A
..........................20
12.2
Part List A
......................................21
12.3
Part List B
......................................22
12.4
Explosion draw B
..........................23
12.5
WIRING DIAGRAM AND PARTS
LIST
.......................................................24
13 TROUBLESHOOTION
.........................26
13.1 Blade and cut diagnosis................26
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Instruction Manual for CS-315C (S827)
03/12/2014
1
1 SSAAFFEETTYY RREEGGUULLAATTIIOONNSS
This machine complies with the national and local accident prevention regulations. Improper
use and/or tampering of the machine will relieve the manufacturer of all responsibility.
1.1 General Safety Advice
Always wear s
uitable eye protection.
Always disconnect the machine from the power source before changing the saw
blade/cutting disk, or performing any maintenance work.
Never expose your hands or limbs to the cutting area while the machine is operating.
Do not shift th
e machine while in operation..
Do not wear, gloves, very loose or long clothing, long and loose sleeves, bracelets,
chains, neck ties; or any other object that could get caught in the machine during
operation
Tie back long hair.
Keep the work area free of
equipment, tools or any other object.
Focus on one task at a time
Keep your hands free; do not carry too many objects in your hands.
Keep your hands clean.
When the machine is not in use, the saw blade should not be moving.
1.2 Blade Guard Safety
The blade g
uard is a self
adjusting cover that prevents contact with the blade. Never
use the machine without the blade guard.
Never handle blade guard while the blade is running.
1.3 Emergencies
In the event of incorrect operation or dangerous conditions, the machin
e may be stopped
immediately by pressing the emergency stop button. This will shut off the machine and will
require resetting of the emergency stop button.
Note: Resetting of machine operation after each emergency stop is achieved by reactivating
the spe
cific restart button.
2
2 MMAACCHHIINNEE DDIIMMEENNSSIIOONNSS
Page 3
Instruction Manual for CS-315C (S827)
03/12/2014
3
3 TTEECCHHNNIICCAALL CCHHAARRAACCTTEERRIISSTTIICCSS
3.1 General Characteristics
4
4 TTRRAANNSSPPOORRTTIINNGG TTHHEE MMAACCHHIINNEE
When transporting in its
own packaging,
use a forklift truck or
hand trolley.
5
5 GGEETTTTIINNGG TTOO KKNNOOWW YYOOUURR MMAACCHHIINNEE
5.1 Disk Head Assembly
The section of the machine composed motor, gear transfer
system, disc or blade, and control handle.
A. Control Lever
A long angled lever with a handle grip
and trigger switch for
starting, raising, and lowering the disk head
B. Transfer Case
The central part of the assembly, housing the gear system
and oil tank
.
Cutting
Capacit
y
0
50mm
100mm
82 x 82mm 110 x 70mm
45
50mm
90mm 80
x 80mm
85 x 70mm
Main Motor
2HP
(
1.5kW) /
3ph /
2P
/ 4P
2HP (
1.5kW) /
3ph
/ 4P/ 8P
2.5HP (1.875kW) / 1ph / 4P
Spindle Speed
2P/ 4P 60HZ -
104
/ 52
RPM
50HZ - 88 /
44 RPM
4P/ 8P 60HZ - 52 /
26 RPM
50HZ
- 44 / 22
RPM
Saw Blade
315 mm
Maximu
m Vise Opening
120 mm
Cooling Pump
1/8 HP
Coolant tank
5 L
Machine Weight
(with stand)
175 Kg
s
Machine Dimensions
(with stand) L x W x H
1020 x 990 x 1830mm
B A
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Instruction Manual for CS-315C (S827)
03/12/2014
5.2 Machine Base
A heavy cast iron structure that supports the miter system,
vise system, and hea
d assembly.
5.3 Vice
A
clamping system that provides the basic support and
security for the work material. Operations are conducted by
hand-wheel, which opens and closes the vise jaws.
5.4 Support Roller
A Device that support longer sized material.
The roller
assists stock moving through the vise.
5.5 Stand
Support structure for the Machine Head Assembly, Machine
Base, and Vise system. The stand also stores the coolant
pump.
5.6 Coolant Pump
Found within the machine stand, the coolant pump
is a self
contained system that includes a tank, pump motor, filters
and hoses.
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Instruction Manual for CS-315C (S827)
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6
6 GGEETTTTIINNGG SSTTAARRTTEEDD
Make sure that the electrical supply and the machines voltage are the same. Refer to
the identification plate on the motor for the correct volt
age.
Use a good quality grounded electrical system.
All internal and/or internal operations, maintenance or repairs, must be performed in a
well-lit area or where there is sufficient light from extra sources so as to avoid the risk of
even slight accidents
.
6.1 Minimum Requirements for Housing the Machine
The Main voltage and frequency complying with the requirements for the machine
s motor.
Environment temperature from
10°C to +50°C.
Relative humidity not over 90%.
6.2 Anchoring the Machine
Position the machine on a firm and level concrete floor.
Maintain a minimum distance of 800mm from the wall to
rear of the machine.
Anchor the machine to the ground, as shown in the
diagram, using screws and expansion plugs or sunken
tie rods that connect through holes in t
he base of the
stand.
Ensuring that it is sitting level.
6.3 Assembly and Setup
Take out the accessories (A) and the
coolant tank (B) from inside of the stand
and set aside for later use.
Lift off the stand (C) and place into the
inten
ded working location (D).
Prepare the machine unit for hoisting
Method one: Use a sling. Carefully wrap the sling (E) around the collar of the movable jaw
and motor mount
Method two: Using lift rings. Attach lifting rings to three points on the base of the machine.
Attach a three-point sling with grab or sling hooks to the lift rings (F).
1
B
A
3
E
2
D
C
F
F
F
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Instruction Manual for CS-315C (S827)
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Place the machine on the top of the stand.
Use an overhead hoist lift the machine unit
Align the four setscrews (G) on the underside of the machine base to their corresponding
holes in the stand.
Direct the setscrews (G) into their matching holes while lowering the machine onto the
stand.
Secure the machine onto the stand using three nuts to the exposed setscrews on the
underside of t
he stand holes.
Attach the coolant tank platform.
Insert platform (H) to the interior of the machine stand.
Align the platform holes (i) to the screw holes (i) on the
interior of the machine stand.
Apply an M8x18x2, washer to each of 2, M8x12,
sc
rews.
Secure the platform (H) to the stand.
Remove the oil fill transport plug from gear transfer case.
Use a wrench to unscrew a M20 X 40 hex head screw
(J) from the oil fill hole (J).
Attach the control handle to the head assembly.
Insert the
threaded end of the control handle into the
gear oil fill hole (J).
Turn the control handle (L) along the shaft to screw in
the control handle (L) until a tight fit.
Align the handle (L) so that the trigger switch (K) point
up. (Refer to image)
Conne
ct the electric wire with the motor.
Locate the open socket (M) at the side of the electrical
box on the top of the motor.
Plug in the control handle cable into the open socket
(M).
Use a wrench to screw in the cable connecter nut (N).
4
G G G
6
J
8
N
M
7
K
L
J
G
5
H
i
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Instruction Manual for CS-315C (S827)
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Attach th
e support roller to the left side of the base.
Place the support roller (P) up next to the machine
base.
Align the 2 slots (O) in the base of the support roller with
the matching screw holes on the base of the machine.
Apply an M10 washer for each of 2 M10x25 hex head
bolts.
Loosely screw the hex head bolts into the aligned slot
(O) and holes.
Adjust the height of the support roller (P). Place a level
across the mouth of the vise and support roller. If a long
level in not available, use a straight bar or piece of
material then place a small level on top. Raise or lower
the support roller until level.
Secure the support roller (P) into place. Use a wrench
to tighten down the 2 hex head bolts.
Attach the bar stop to the vise.
Insert the thread end of the long rod (R) into the side of
the vise.
Turn the long rod clockwise until snug.
Use a wrench to turn the M12 hex nut (Q) on the long
rod (R) counter-clockwise, so that bar stop unit is
secure.
Attach the cover plate to machine stand.
Place
plate (S) next to the hole at the base of the
machine stand.
Align the plate (S) holes the stand holes.
Use 4, M5X6 screws to secure into place.
Assemble the coolant tank
Insert the coolant pump (X) into the coolant tank (T).
Apply an M6 washer to
each of 2 M6x20 screws (U).
Secure pump (X) to tank (T) with prepared screws (U).
Place the hose clamp (V) onto the 0.375 flow tube (W).
Connect the flow tube (W) to the hose connector (V).
Use a flat head screwdriver to tighten the hose clamp
(V).
11
10
9
O
P
Q
R
S
12
X
U
V
W
T
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Instruction Manual for CS-315C (S827)
03/12/2014
Install the coolant tank
Orient the coolant pump (X) towards the rear opening of
machine stand.
Place the coolant tank (1A) onto the coolant platform
(H). The coolant tank (1A) contains a divider that forms
a trough in the bottom of the tank.
This trough fit over
the vertical lip of the coolant platform (H).
Insert one end of the 0.5 drain hose (Y) onto the hose
connector (1B) on the underside of the machine base.
Place the other end into the insert (Z) of the coolant tank
(1A).
Attac
h the rear plate to the back of the stand.
Place rear plate (1C) across the back of the machine
stand.
Align the plate holes (1D) with the set of 4 holes towards
the top of the machine stand.
Apply an M8 washer to each of 4 M8x25 screws.
Secure with 4 scre
ws and washers.
Install the splash plates
Insert a splash plate (1E) onto the front sidewall of
machine base.
Align the 2 slots (1F) in the base of the splash plate with
the matching screw holes on the machine base.
Apply a washer for each o
f 2 hex socket head screws
M8x20
.
Loosely screw the socket hex head screws into the
aligned slot (1F) and holes.
Adjust the splash plate (1E) to the proper position and
tighten down the screws to secure.
Insert a
longer one of
splash plate (1G) onto th
e rear
sidewall of the machine base. This plate need not be
secured with screws to allow free movement or
convenient removal.
7
7 RREECCOOMMMMEENNDDAATTIIOONNSS AANNDD AADDVVIICCEE
13
14
1A
X
Z
Y
14
H
1B
1C
Y
1D
1D1E1F
1G
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Instruction Manual for CS-315C (S827)
03/12/2014
7.1 General Advise Before Using the Machine
This machine is designed to cut metal construction materi
als of different shapes and
profiles. The materials may be required for fabrication workshops, machinist shops, and
general construction work.
Limit the machines use to a single operator.
To obtain good running-in of the machine it is advisable to start
using it at intervals of
about half an hour. This operation should be repeated two or three times, after which the
machine may be used continuously.
Always check that the workpiece is securely clamped and that long pieces are suitably
supported.
Do not us
e a disk size that is outside the limits of the machine specifications.
Immediately release the start/run/trigger button if the disk should get stuck in a cut.
Switch off the machine before raising the machine head. Then open the vise and
remove the wor
kpiece. Lastly, check the disk teeth for any damage. If any of the teeth
are broken, replace the saw blade.
Before carrying out any repairs of the machine, consult a technician.
7.2 Operator Position
The operator should stand in front of the machine usi
ng a
single hand to grip the control handle.
7.3 Deactivating the Machine
If the machine is to be inactive for a long period, prepare the machine as follows:
Detach the plug from the electric supply panel
Release the head return spring
Empty the coo
lant tank
Carefully clean and grease the machine
If necessary, cover the machine.
7.4 Dismantling
General rules
Before disposing of the machine, the machine should be broken down and separated into
the 3 categories as follows:
Cast iron or ferrous materials
: These materials should be of single composition, without
combination or attachment to other types of materials. This is a recyclable material. The
materials may be sent to metal scrap and recycling centers.
Electrical components: This includes cables
and electronic parts (magnetic cards, etc.).
These materials may be considered as urban waste. Give the materials to your local
public waste disposal service.
Old mineral, synthetic and/or mixed oils: Blend oils and greases are special refuse.
Have t
hese collected by a service specializing in oil disposal.
Note: Standards and legislation for waste disposal is in a state continuous change and
evolution. The user must be informed of current regulation for waste disposal of machine
Page 10
Instruction Manual for CS-315C (S827)
03/12/2014
tools, as they may
differ from those described above. They are to be considered as general
guideline.
8
8 AADDJJUUSSTTIINNGG TTHHEE MMAACCHHIINNEE
BEFORE PERFORMING THE FOLLOWING OPERATIONS, THE ELECTRIC POWER
SUPPLY AND THE POWER CABLE MUST BE COMPLETELY DISCONNECTED.
8.1 Disk Head
If excessive axial play is found on the hinge, it will be sufficient to tighten the screws.
Pay attention and avoid making the joint too tight.
8.2 Adjusting the Mitering Lock Lever
The lock lever may require adjustment when the lever is
limited by the machine base and it fail to adequately secure
the miter angle for machine head. If there is insufficient
brakeage of the lock lever:
Loosen screw (A)
Support the bushing (B) so that it does not drop in
position.
Pivot the lever (C) to unlock side to allow more r
ange of
motion.
Then tighten the screw (A).
8.3 Changing the Disk
To changed the disk:
Release the mobile guard (A) by removing the hex
socket screw (B).
Rotate the mobile guard (A) back.
Place a block of wood into the vise.
Lower the machine head to rest
the cutting disk or saw
blade on the block of wood.
Use a hex wrench to remove the hex socket screw (C),
Rotate the disk in the clockwise direction to loosen it
(because it has a left-handed thread).
Remove the disk or blade (D) and flange (E) from the
h
ead assembly.
Slip off the flange (E) from the disk (D).
Place the flange onto the replacement disk or blade (D).
Continue the replacement of the disk in reverse order of
removal of the disk.
8.4 Cleaning and Accessing the Coolant System
Pull out the drain
hose from the filter (A).
Pull out the coolant tank from the coolant platform in the
stand.
Remove the filter (A) from the tank
Pour out the coolant
Wash out the dirt and debris.
Replace the filter (A).
Fill with coolant solution of 1:10 ratio of coola
nt to water
Replace the coolant tank in reverse order of removal.
C
A
B
A
C
B
D
E
A
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Instruction Manual for CS-315C (S827)
03/12/2014
9
9 TTHHEE OOPPEERRAATTIIOONN CCYYCCLLEE
Before operating all the main parts of the machine must be set to optimum conditions (see
the chapter on
regulating the machine )
9.1 Miter Angle
Use the miter lock le
ver (A) to release the disk head
assembly.
Rotate the disk head assembly to the correct miter
angle.
Check the miter angle on the angle indicator (B) below
the vise
Use the miter lock lever (A) to lock in the miter angle.
9.2 Vise Operation
The qui
ck clamp vise lever allows the operator to quickly clamp and unclamp work-pieces of
same width. This allows for efficient use of machine for loading and feeding forward work
-
pieces.
Use the hand wheel to open and close the vise jaw for work
pieces th
at vary in width.
Rotate the hand-wheel (A) counter-clockwise to open
the vise.
Rotate the hand-wheel (A) clockwise to close and
approach the vise jaw (C) to the work pieces.
Use the vise lever to quickly clamp and unclamp work
pieces of the same width
.
Rotate the vise lever (B) clockwise to clamp the work
piece.
Rotate the vise lever (B) counter-clockwise to unclamp
the work-piece.
9.3 Loading the Work-piece
Use the vise hand-wheel to open the vise wider than the width of the work-piece.
Measure and mark
off the length of material desired to be cut-off.
Place the work-piece on the flat surface in between the vise jaws.
Slide the work-piece across the vise so that the length mark lines up with the blade or
disk.
Press the work-piece up against the back vise
jaw.
Use the vise hand-wheel to clamp the work-piece.
If repetitive cuts are required for material of the same width:
Use the vise hand-wheel to approach the work-piece, but leave an approximate 5mm
gap between the mobile vise jaw and the work-piece.
The
n use the vise lock lever to clamp and unclamp the work-piece.
A
A
B
B
C
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Instruction Manual for CS-315C (S827)
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9.4 Setting Cutting Length
Setting the cutting length removes the need to repeatedly measure work-pieces for repetitive
cuts of a single length.
Measure and mark off the length of material desire
d to
be cut-off.
Load the work-piece.
Line up the cut
Clamp the work-piece.
Loosen the hex nut at the base of the bar riser (A).
Slide the bar riser (A) along the long rod (C) so that the
tip of stop bar (B) touches the end of the work-piece.
Tighten the h
ex nut at the base of the bar riser (A).
The stop bar in use
Cut off the first length of work-piece.
Unclamp the work-piece
Slide the work-piece forward until it reaches tip of the stop bar (A).
Clamp the work-piece.
Then proceed with the operation cycle
9.5 Operation Cycle
Set the miter cut angle, if necessary
Open the vise, if necessary
Load the work-piece
Clamp the work-piece
Adjust the bar stop for cutting length, if necessary
Check that the main power light is ON (A).
Set the speed (C).
Set the cool
ant switch (B).
Grasp the control handle (G).
Press the trigger switch (F) to start.
Pull down the control handle (G). Apply a steady and
constant pressure.
After cut off
Raise control handle slowly
Press the stop button (D)
Use vise lever to open the v
ise
Remove or feed the work-piece forward
Repeat operation cycle, if necessary
The chopper is now ready to start work, bearing in mind that the CUTTING SPEED and the
TYPE of DISC
combined with a suitable descent of the head are of decisive importanc
e
for cutting quality and for machine performance.
When starting to cut with a new disk, in order to safeguard its life and efficiency, the first two
or three cuts must be made while exerting a slight pressure on the part, so that the time
taken to cut is
about double the normal time.
F
G
A B C
D
E
C
B
A
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Instruction Manual for CS-315C (S827)
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Press the red emergency button (E) when there are conditions of danger of malfunctions in
general, so as to stop machine operation immediately.
110
0 RROOUUTTIINNEE AANNDD SSPPEECCIIAALL MMAAIINNTTEENNAANNCCEE
THE MAINTENANCE SCHEDULE AS BEEN DIVIDED INTO DAILY, WEEKLY, MONTHLY,
AND SIX-MONTHLY INTERVALS. NEGLECTING THE MACHINE MAINTENANCE WILL
RESULT IN PREMATURE WEAR AND POOR PERFORMANCE.
10.1 Daily Maintenance
Make a general cleaning by removing dust and shavings from the machine.
Top off the coolant.
Inspec
t the disk/saw blade for wear.
Raise the head into a high position to reduce stress on the return spring.
Check that the shields and emergency stops are in good working order.
10.2 Weekly Maintenance
Thoroughly clean the machine including the coolant tank.
Cle
an and grease the vice screw and sliding surfaces.
Clean the housing for disk/saw blade.
Sharpen the saw teeth.
10.3 Monthly Maintenance
Check that all screws on the motor, the pump, the vise jaws, and the guard are tight and
secure.
Check that the guard is fr
ee from defect.
Grease the hinge pin for the head assembly.
10.4 Six-Monthly Maintenance
Change the oil in the reduction unit using oil type
DN SUPER GEAR 460
by
IDEMITSU
or
DAPHON
or equivalent oil, proceeding as follows:
Remove the connecting plug from the
electric box and
unscrew the control handle.
Drain off the old oil from the drain hole (A)
Pour in new oil of to the mark (B), through the hole for the
control handle, keeping head in a horizontal position.
Reassemble all the parts.
Check continuity o
f the equipotential protection circuit.
10.5 Oils for Lubricating Coolant
Considering the vast range of products on the market, the user can choose the one most
suited to his own requirements, using as reference the type SHELL LUTEM OIL ECO.
THE MINIMUM PERCENTAGE OF OIL DILUTED IN WATER IS 8~10%.
10.6 Oil Disposal
Oil products must be disposed in a proper manner following local regulations. Please refer
to
Machine disposal.
10.7 Special Maintenance
Special maintenance operations must be carried out by skilled personnel. However, we
advise contacting dealer and/or importer the term special maintenance also covers the
resetting of protection and safety equipment and devices.
A
B
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Instruction Manual for CS-315C (S827)
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111
1 MMAATTEERRIIAALL CCLLAASSSSIIFFIICCAATTIIOONN AANNDD CCHHOOIICCEE OOFF TTOOOOLL
The goal is to produce an excellent quality cut and efficiency during multiple identical cuts.
The user must consider the quality of material in respect to hardness, shape, and thickness
to determine the proper descent rate, blade/disk speed, and saw blade/disk type. A
harmonious combination of materi
al, rate, speed, and type are required to achieve a quality
cut. So great care and thought should be made into planning for a single operational cycle
then efficiency can be achieved for multiple identical operations. With good knowledge of
machine specification and careful consideration and common sense, the user can attain the
goal and overcome any problem that may appear from time to time.
11.1 Disk Structure
The most commonly used disks are made of extra high speed steel (HHS/Mo5+Co5) with a
treated tooth
, which differentiates them from the former on account of the high value of
structural resistance, greater resistance to seizing, absence of stress in the mass and a
better holding of lubricating coolant during work.
11.2 Choosing the Saw Blade
Choose a tooth
pitch that is suitable for the workpiece. Please refer to Tooth pitch .
Thin walled or variable section work pieces such as profiles, pipes, and plates require
closed toothing, so that at least 3~6 teeth are in contact with the material while cutting.
La
rge solid or transverse sections require widely spaced toothing to allow for greater
volume of the shavings and better tooth penetration.
Soft materials or plastics such as light alloys, mild bronze, Teflon, wood, etc., require
widely spaced toothing to av
oid clogging.
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Instruction Manual for CS-315C (S827)
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11.3 Type of Disks
The disks differ essentially in their constructive characteristics, such as:
Tooth shape
Tooth cutting angle
Tooth shape
The profile of the toothing depends on the size, shape and thickness of the section to be cut,
either straight or at a
n angle.
It may also vary according to the pitch, but not so distinctly as to make this an element for
classification.
Fine toothing is to be chosen for cutting small sections with a profiled shape and tubular
sections with thin walls (2-5mm depending on t
he material).
Large toothing is suitable for cutting medium and large solid sections or fairly thick profiled or
tubular sections (over 5mm).
A
toothing
:
AW
toothing
:
Normal fine toothing
Fine toothing with alternate side rake
TYPES OF STEEL
CHARACTERISTICS
USE
I D
UNI DIN
F
AF NOR
GB
SB
USA
AISI-SAE
Hardness Hardness
BRINELL ROCKWELL R=N/mm2
HB HRB
Construction
Steels
Fe360 St37
Fe430 St44
Fe510 St52
E24
E28
E36
---43
50
----
----
----
116 67 360÷480
148 80 430÷560
180 88 510÷660
Carbon Steels
C20 CK20
C40 CK40
C50 CK50
C60 CK60
XC20
XC42H1
----
XC55
060 A 20
060 A 40
----
060 A62
1020
1040
1050
1060
198
93 540÷690
198 93 700÷840
202 94 760÷900
202 94 830÷980
Spring steels
50CrV4 50CrV4
60SiCr8 60SiCr7
50CV4
----
735 A 50
----
6150
9262
207 95 1140÷1330
224 98 1220÷1400
Alloyed s
teels for
Hardening and tempering
and for ni
triding
35CrMo4
34CrMo4
39NiCrMo4 36NiCrMo4
41CrAlMo4 41CrAlMo7
35CD4
39NCD4
40CADG12
708 A 37
----
905 M 39
4135
9840
----
220 98 780÷930
228 99 880÷1080
232
100 930÷1130
Alloyed case hardening
steels
18NiCrMo7 ----
20NiCrMo2 21NiCrMo2
20NCD7
20NCD2
En 325
805 H 20
4320
4315
232 100 760÷1030
224 98 690÷980
Steel for bearings
100Cr6 100Cr
6
100C6
534 A 99
52100 207 95
690÷980
Tool steel
52NiCrMoKU
56NiCrMoV7
C100KU C100W1
X210Cr13KU X210Cr12
58SiMo8KU
----
----
----
Z200C12
Y60SC7
----
BS 1
BD2
BD3
----
----
S-1
D6-D3
S5
244 102 800÷1030
212
96
710÷980
2
52 103
820
÷10
60
2
44 102 800÷103
0
Stainless steel
X12Cr13 4001
X
5CrNi1810 4301
X8CrNi1910
----
X8CrNiMo1713 4401
----
Z5CN18.09
----
Z6CDN17.12
----
304 C 12
----
316 S 16
410
304
----
316
202 94
670÷
885
202 94
590÷685
202 94
540÷685
202 94
490÷685
Copper alloys
Special brass
Bronze
Aluminium copper alloy G-CuAl11Fe4Ni4 UNI 5272
Special manganese/silicon brass G-CuZn36Si1Pb1 UNI5038
Phosphor bronze G-CuSn12 UNI7013/2a
220 98
620÷
685
140 77
375÷440
120 69
320÷410
100 56,5
265÷314
Cast iron
Gray pig iron G25
Spheroidal graphite cast iron GS600
Malleable cast iron W40-05
212 96
245
232 100
600
222 98
420
Page 16
Instruction Manual for CS-315C (S827)
03/12/2014
B
toothing
:
BW
toothing
:
Normal large toothing with or without Large toothing with alternating
side rake
shaving breaking inclusion.
C(HZ) toothing
:
Large foothing with roughing tooth with rake on both sides, alternating with a finshing tooth
without rake. The toughing tooth is 0.15-.30 mm higher.
Added toothing:
Disk made in the w
ay are used for cutting non-ferrous metals, such as light alloys, and
plastics, and above all in woodworking. The teeth are hard metal (HM) plates brazed onto
the body of the disk; there are various types and shapes and, considering the vastness of
the fi
eld, the topic is not developed further here.
Tooth cutting angle
Each tooth has two cutting angles
:
-
: front rake angle
-
: rear rake angle
T
3 4 5 6 7 8 9
10
12
14
16
p
1,3 1,6
2,1 2,5 2,9 3,4 3,8 4,2 5,1 5,9 7,2
d
1,5
2
2,5
3
3,5
4
4,5
5 6 7 8
h = 0,2 mm
h = 0,3 mm
R
akes vary
in accordance to material to be cut.
11.4 Choosing the Tooth Pitch
Se
lect tooth pitch based on, harness of the materials, dimensions of the section, and,
thickness of the wall
11.5 Cutting and Advance Speed
The cutting speed (m/min) and the advance speed (cm2/min= area traveled by the disk teeth
when removing shavings) are limited by the development of heat close to the tips of the
teeth.
The cutting speed is subordinate to the resistance of the material (R= N/mm2), to its
hardness (HRC) and to the dimensions of the widest section.
Page 17
Instruction Manual for CS-315C (S827)
03/12/2014
To high an advance speed (=disk descent) tends to cause the disk to deviate from the ideal
cutting path, producing non-rectilinear cuts on both the vertical and the horizontal plane.
11.6 Running in the Disk
When cutting for the first time, it is good practice to run in the tool making a series of cuts at
a low advance speed (=30~35 cm2/min on material of average dimensions with respect to
the cutting capacity and solid section of normal steel with R= 410-510 N/mm2), generously
spraying the cutting area with lubricating coolant.
11.7 Cutting Speed Chart
Cuttin
g speeds according to disk diameter
KEY
T Tooth pitch in millimeters d Diameter of the tooth fillet cone distance
Av mm/min Advance in millimeters per minute h Tooth protrusion
Vt m/min Cutting speed in meters per minute
Front rake
Az Tooth advance
Rear rake
Ng/min Number of revs per minute N/mm Ultirnate tensile stress
Z Number of teeth on th
e disk a-f Flat parts of the cutting edge
p Tooth depth
Tube diameter of profile width
Page 18
Instruction Manual for CS-315C (S827)
03/12/2014
11.8 Recommended Cutting Parameters
Mild steel
R=350-500 N/mm
2
Semi-hard steel
R=500-700 N/mm2 Hard steel
R=750-950 N/mm2 Extra-hare steel
R=950-1000 N/mm2 Hear-treated steel
R=950-1300 N/mm2 Austentic stainless steel
R=500-800 N/mm
2
Martensitic stainless Steel
R=500-800 N/mm
2
Grey cast iron
Aluminium and alloys
R=200-400 N/mm2 Aluminium and alloys
R=300-300 N/mm2 Copper
R=200-350 N/mm2 Phosphor bronze
R=400-600 N/mm2 Hard bronze
R=600-900 N/mm2 Brass
R=200-400 N/mm2 Alloyed brass
R=200-400 N/mm2 Titanium and alloys
R=300-800 N/mm
2
Tube and beams 0.05 D
R=300-600 N/mm2 Tubes and beams 0.025 D
R=300-600 N/mm
2
20° 18° 15° 12° 10° 12° 15° 12° 22° 20° 20° 15° 12° 16° 12° 18° 18° 15°
CUTTING
ANGLES
8° 8° 8° 6° 6° 8° 6° 8°
10°
8°
10°
8° 8°
16° 16°
8° 8° 8°
°T mm
5
4 4 3 2 4 4 4 6 5 6 5 4 5 5 4 3 2
Vt m/1
50 30 20 15 9 20 20 25 1100 200 400 400 120 600 500 50 19 35
10-20
Av
mm/1
160 130 110 60 35 50 50 100 1800 400 600 800 160 1100 700 160 130 130
°T
mm
7
6 6 4 3 6 6 6 8 7 8 7 8 6 7 4 4 3
Vt m/1
45 30 20 15 9 19 19 23 1000180 350 400 110 600 400 45 18 30
20-40
Av
150 120 110 60 33 45 45 100 1700 400 600 700 150 1100 600 150 120 110
°T
mm
10
9 8 6 4 8 8 8 12 10 11 10 8 10 10 6 5 4
Vt m/1
45 25 18 14 9 18 18 22 900 160 300 350 100 550 350 45 18 30
40-60
Av
mm/1
140 110 100 50 30 45 45 90 1600 350 550 700 140 1000 600 140 110 110
°T mm
12
12 11 9 6 11 11 11 16 12 14 12 10 12 12 10 6 5
Vt m/1
40 25 17 14 8 17 17 20 800 160 250 300 90 550 350 45 17 30
60-90
Av
130 110 50 50 28 40 40 80 1400 300 550 600 130 900 500 130 110 110
°T
mm
14
14 14 12 8 14 14 14 18 14 17 14 12 16 16 12 6 5
Vt m/1
40 20 15 13 8 15 15 19 700 140 200 250 70 500 300 40 16 28
90-110
Av
mm/1
110 100 80 45 25 40 40 880 1300 300 500 600 110 900 500 110 100 100
°T mm
16
16 16 14 10 16 16 16 20 16 18 16 14 18 18 14 8 6
Vt m/1
35 20 14 13 7 14 14 17 600 130 150 200 60 500 300 35 16 26
110
-
130
Av
100 90 70 45 25 35 35 70 1100 250 500 500 100 800 400 100 90 90
°T
mm
18
16 16 14 12 16 16 16 20 16 20 18 16 18 18 16 10 6
Vt m/1
30 15 12 12 7 12 12 16 500 130 120 150 50 450 200 30 15 24
SECTION TO BE CUT ( IN MM )
130
-
150
Av
mm/1
90 80 60 40 22 35 35 60 900 250 400 400 90 800 400 90 80 80
RECOMMEDED
LUBRIFICANTS
Emulsion
Cutting oil
Dry
Kerosene
Dry
Emulsion
Cutting oil Emulsion
Page 19
Instruction Manual for CS-315C (S827)
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112
2 EEXXPPLLOOSSIIOONN DDRRAAWW AANNDD PPAARRTT LLIISSTTSS
12.1 Explosion draw A
Page 20
Instruction Manual for CS-315C (S827)
03/12/2014
12.2 Part List
A
Item. Description
Size Q'TY
A42 Spindle shaft
1
A43 Worm gear
1
A44 Lock Nut
1
A45 Stopper
1
A46 Vise bench
1
A47 Hex socket cap screw
M5x25
3
A48 Swing arm (base)
1
A49 Support rod
1
A50 Vise clamp
1
A51 Groove jaw
1
A52 Small groove jaw
1
A53 Trigger switch with handle 1
A54 Nut
M10
1
A55 Control handle rod
1
A56 Nut
M20
1
A57 Nut
M20
1
A58 Machine head
1
A59 Ball bearing
6205zz
1
A60 Bal
l bearing
6301zz
1
A61 Rubber sheet
1
A62 Hex cap screw
M8x20
4
A63 Washer
5/16"
4
A64 Flange
1
A65 Oil seal
1
A66 Worm shaft
1
A67
Coupling 1
A68 Motor
1
A69 Wire terminal clamp
4
A70 Control w
ire
1
A71 Hex cap screw
M8x20
4
A72 Washer
5/16"
4
A73 Oil
pilot
PT1/2"
1
A74 Set screw
PT1/4"
2
A75 Shaft
1
A76 Bushing
1
A77 Hex cap screw
M12x55 1
A78 Nut
M12
1
A79 Lock bolt with knob
1
A80
Length setting rods
bracket
1
A81 Upper length setting rod
1
A82
Lower len
gth setting rod
1
Item Description
Size
Q'TY
A01 Lock handle
1
A02 Lock Nut
1
A03 Shaft
1
A04 Machine base
1
A05 Roller bracket
1
A6-1
Hex head screw
2
A07 Roll
er 1
A08
C-
clip
S-12 2
A09 Hex socket cap screw
M8x20
1
A10 Washer
5
/16"
1
A11 Hand
le
wheel
1
A12 Pin
1
A13 Bearing bushing
1
A14 Bearing
1
A15 Bushing
1
A16 Leading screw
1
A17 Lock handle
1
A18 Sliding v
ise
1
A19 Washer
1
A20 Spring
1
A21 Plate
1
A22 Hex socket cap screw
M12x25 2
A23 Washer
5/16"
2
A24 Hex socket cap screw
M8x20
2
A25 Spring
1
A26 Washer
5/16"
1
A27 Hex socket cap screw
M8x20
1
A28 Switching handle
1
A29 Washer
1/4"
1
A30 Hex socket cap screw
M6x12
1
A31 Washer
1/4"
1
A32 Nut
M8
1
A33 Switching p
late
1
A34
C-
clip
A35 Blade shield
1
A36 Screw
M5x10
7
A37 Plate
A38 Blade cover
1
A39 Hex socket cap screw
M12x35 1
A40 Fixing flange
1
A41 Saw blade
1
Page 21
Instruction Manual for CS-315C (S827)
03/12/2014
12.3 Part List B
Item
Description
Size
Q'TY
A83
Nut
1
A84
Lock bolt with knob
1
A85
Filter plate
1
A86
Lift ring
3
A87
Drainage
1
A88
Washer
5/16"
2
A89
Hex socket cap screw M8x25 2
A90
Hex socket cap screw
1
A91 Supporter
1
A92
Washer
5/16"
2
A93
Hex cap screw
M8x20 2
A94
Screw M5
4
A95
Stop button
1
A96
Star
t button
1
A97
Emergency switch
1
A98
2/4P selection switch
1
A99
Pump selection switch
1
A100
Control box panel
1
A101
Washer
5/16"
2
A102
Hex socket cap screw M8x20 2
A103
Electric control box
1
A104
Control box button plate 1
A105
Magnetic connector
1
A106
Fuse set
1
A107
Cover plate
1
A108
Transformer
1
A109
Relay
1
A110
Plate
1
A111
Support p
late
2
A112
Washer
5/16"
2
A113
Hex socket cap screw M8x16 2
A114 Screw M5
2
A
117
Cover
2
A
118
Screw 2
A119
Oil
seal
1
A120
Rubber plate
1
A121
Rubber plate
1
A122
Holder plate
1
A123
Anti-dust plate
1
A124
Plate
1
Item
Description
Size
Q'TY
B01 Stand
1
B02 Nut
M6
4
B03 Washer
1/4"
4
B04 Support plate
1
B05 Washer
1/4"
4
B06 Hex cap screw
M6x
15 4
B07 Coolant tank
1
B08 Hose
1
B09 Hose clamp
1
B10 Washer
1/4"
2
B11 Hex socket cap screw M6x16 2
B12 Coolant pump
1
B13 Connect
ing bolt
1
B14 Hose clamp
1
B15 Hose
1
B16 Hose clamp
1
B17 Valve
1
B18 Wire
1
B19 Hex c
ap screw
M6x15 4
B20 Washer
1/4"
4
B21 Hex cap screw
M6x15 2
B22 Washer
1/4"
2
B23 Support plate
1
B24 Screw
M5x6
4
B25 Cover plate
1
B26
Collar 1
Page 22
Instruction Manual for CS-315C (S827)
03/12/2014
12.4 Explosion draw B
Page 23
Instruction Manual for CS-315C (S827)
03/12/2014
12.5 WIRI
NG DIAGRAM AND PARTS LIST
Motor connection
Item
name
Description and
function
Technical
data
Quantity
Supplier
Suppliers
reference
Remarks
FU1
FU2
FU3
FU4
Fuses
Fuses
base
30x6.2mm 250V
15
A
15
A
15
A
2A
10A 4P
1
1
1
1
1
JENN FENG
S15A
FSB-104
K1
Contactor
Coil 24V
It=25A
220V 2.2kw
400V 4.0kw
1
NHD
C-12D
CE
ICE 158
-1
BS 5424
-1
VDE 0660
JI3 8325
KR
Relay
250VAC
5A
1
BETA
MY
-2N
AC 24V
CE
CSA
TC
Transformer
35VA
23
0/24V
,400V/24V
1
TAI CHUNG
66 , 57
SB1 Emergency Stop
250V 6A
1
KEDU
HY57B
CE
CUS
SB2
SB3
OFF
button
Start button
250V 6A
1
1
MACK
ABF-221b
ABLFS-22
1a 30V
CE
CUS
SB4
T
rigger
switch
15A 1/2HP 125 250VAC
0.6A 125VDC 0.3
A
250VDC
1
OMRON
V-15-
1A5
CE
CUS
SB5
Pump switch
250V
1
GIKOKA
OSS-22
CE
CUS
SA1
Hi/Low speed
select switch
440V
5kw
1
KEDU
ZH-HC
-5
CE
CUS
M1
Motor
400V,230V/ (
1.5kw
) 2HP
3ph/2P/4P
400V
,230V/ (
1.5kw
)2HP
3ph/4P/8P
1
KUOSHUAY
KST058
KST063
M2
Coo
lant pump
400V
/ 3ph
, 230V/1PH
(
0.09kw
)
1/8HP
1
KUOSHUAY
Page 24
Instruction Manual for CS-315C (S827)
03/12/2014
12.6 WIRING DIAGRAM AND PARTS LIST
Item
name
Description and
function
Technical
data
Quantity
Supplier
Suppliers
reference
Remarks
FU1
FU2
FU3
Fuses
Fuses
base
20
A
20
A
2A
10A 3
P
1
1
1
1
BOSS MANN
Thining
ETI
FNQ-aM
FNQ-aM
KTK-gG
VKC-10
CE
CSA
CUS E300304
K1
Contactor
Coil 24V
It=25A
220V 2.2kw
400V 4.0kw
1
NHD
C-18D
CE
ICE 158
-1
BS 5424
-1
VDE 0660
JI3 8325
KR
Relay
250VAC
5A
1
BETA
BMY
-5-2C
AC 24V
CE
CUS-E115915
TC
Transformer
35VA
22
0 /
24V
1
TAI CHUNG
PT-66
SB1 Emergency Stop
250V 6A
1
KEDU
HY57B
CE
CUS
SB2
SB3
OFF
button
Start button
250V 6A 2a
1
1
MACK
ABF-221b
ABLFS-22
1a 30V
CE
CUS
SB4
T
rigger
switch
15A 1/2HP 125
250VAC
0.6A 125VDC 0.3A
250VDC
1
OMRON
V-15-
1A5
CE
CUS
SB5
Pump switch
250V
1
GIKOKA
OSS-22
CE
CUS
MB
Protector
30A
250V
1
YEU SHENG
OC
CE
UL
CUL
M1
Motor
220V / 2.5 HP
1ph / 4Pole
1
KAI SHEN
M2
Coolant pump
220V / 1/8 HP
1ph / 4Pole
1
KAI SHEN
Page 25
Instruction Manual for CS-315C (S827)
03/12/2014
113
3 TTRROOUUBBLLEESSHHOOOOTTIIOONN
This chapter lists the probable faults a
nd malfunctions that could occur while the machine is
being used and suggests possible remedies for solving them.
The first paragraph provides diagnosis for TOOLS and CUTS, the second for ELECTRICAL
COMPONENTS.
13.1 Blade and cut diagnosis
FAULT
PROBABLE CAUSE
REMEDY
TOOTH BREAKAGE
Too fast advance
Wrong cutting speed
Wrong tooth pitch
Low
quality
disk
Ineffective gripping of the part in the vise.
Previously broken tooth left in the cut.
Cutting resumed on a groove made
previously
.
Insuffici
ent lubricating refrigerant or
wrong emulsion.
Sticky accumulation of material on the
disk.
Decrease advance, exerting less cutting
pressure.
Change disk speed and/or diameter.
See chapter
Material
classification
and
choice of disks
and the Table of c
utting
speed s according to disk diameter.
Choose a suitable disk.
See chapter
Material classification and
choice of disks
.
Use a better
quality
disk.
Check the gripping of the part.
Accurately remove all the parts left in.
Make the cut elsewhere, tu
rning the part.
Check the level of the liquid in the tank.
Increase the flew of lubricating
refrigerant, checking that the hole and
the liguid outlet pipe are not blocked.
Check the blend of lubricating coolant
and choose a better
quality disk.
PREMATURE
DISK
WEAR
Wrong running in of the disk .
Wrong cutting speed.
Unsuitable tooth profile.
Wrong tooth pitch.
Low quality disk.
Insufficient lubricating refrigerant.
See chapter
Material classification and
choice of disks
in the paragraph on
Running in the disk.
Change disk speed and / or diameter.
See Chapter
Material classification and
choice of disks
and the Table of cutting
speeds according to disk diameter.
Choose a suitable disk. See Chapter
Material classification and choice of
disks
in the paragraph on Type of disks.
Choose a suitable disk.
See Chapter
Material classification and
choice of disks
.
Use a better quality disk.
Check the level of the liquid in the tank.
Increase the flow of lubricating
refrigerant, checking that the hole and
the liquid outlet pipe are not blocked.
Page 26
Instruction Manual for CS-315C (S827)
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FAULT
PROBABLE CAUSE
REMEDY
CHIPPED DISK
Hardness, shape or flaws in the material
(oxides, inclusions, lack of homogeneity,
etc
)
Wrong cutting speed.
Wrong tooth pitch.
Vibrat
ions
Disk incorrectly sharpened.
Low quality disk.
Incorrect emulsion of the lubricating
R
efrigerant.
Reduce the cutting pressure and/or the
advance.
Change disk speed and/or diameter. See
Chapter
Material classification and
choice of disks
and the T
able of cutting
speeds according to disk diameter.
Choose a suitable disk.
See Chapter
Material classification and
choice of disks
.
Check gripping of the part.
Replace the disk with one that is more
suitable and correctly sharpened.
Use a better
quality disk.
Check the percentage of water and oil in
the emulsion.
DISK VIBRATION
Wrong tooth pitch.
Unsuitable tooth profile.
Ineffective gripping of the part in the vise.
Dimensions of the solid section too large
with respect to the maximum admissib
le
cutting dimensions.
Disk diameter incorrect and/or too large.
Choose a suitable disk.
See Chapter
Material classification and
choice of disks
.
Choose a suitable disk.
See Chapter
Material classification and
choice of disks
in the paragraph on Type
o
f disks.
Check the gripping of the part.
Abide by the instructions.
Decrease the disk diameter, adapting it
to the dimensions of the part to be cut,
the cutting part of the disk must not be
too large for the shape of the part to be
cut.
RIDGES ON THE
CUTTING SURFACE
Disk diameter incorrect and/ or too large.
Ineffective gripping of the part in the vise.
Too fast advance.
Disk teeth are worn.
Insufficient
lubricating
refrigerant.
Toothing does not unload shavings well.
Decrease
the disk diamet
er, adapting it
to the dimensions of the part to be cut,
the cutting part of the disk must not be
too large for the shape of the part to be
cut. Check the gripping of the part.
Decrease advance, exerting less cutting
pressure.
Sharpen the tool.
Check the
level of the liquid in the tank.
Increase the flow of lubricating
refrigerant, checking that the hole and
the liquid outlet pipe are not blocked.
Choose a blade with a larger tooth pitch
that allows better unloading of shavings
and that holds more lubricat
ing
refrigerant.
Page 27
Instruction Manual for CS-315C (S827)
03/12/2014
FAULT
PROBABLE CAUSE
REMEDY
CUT OFF THE
STRAIGHT
Too fast advance.
Ineffective gripping of the part in the vise.
Disk head off the straight.
Disk sides differently sharpened.
Disk thinner than the
commercial
standard.
Dir
t on the gripping device.
Decrease advance, exerting less cutting
pressure.
Check the gripping of the part which may
be moving sideways.
Adjust the head.
Choose tool quality carefully in every
detail as regards type and construction
characteristics
.
Carefu
lly clean the laying and contact
surfaces.
BLADE STICKS IN
THE CUT
Too fast advance.
Low cutting speed.
Wrong tooth pitch.
Sticky accumulation of material on the
disk.
Insufficient
lubricating
refrigerant.
Decrease advance, exerting less cutting
pr
essure.
Increase speed.
Choose a
suitable disk.
See Chapter
Material classification and
choice of disks
.
Check the blend of lubricating coolant
and choose a better
quality
disk.
Check the level of the liquid in the tank.
Increase the flow of lubricating
refrigerant, checking that the hole and
the liquid outlet pipe are not blocked.
Page 28
Instruction Manual for CS-315C (S827)
03/12/2014
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