How it Works
HAFCO-METALMASTER
Loading...
S827
Instruction Manual
28 pgs3.69 Mb0

HAFCO-METALMASTER S827 Instruction Manual

Download
INSTRUCTION MANUAL
Page 1
03/12/2014
CS-315C
MetalMaster Cold Saw, Includes Stand (240V)
110 x 70mm
S827
Table of Contents
Page 2
03/12/2014
1 SAFETY REGULATIONS
1.1 General Safety Advice
1.2 Blade Guard Safety
1.3 Emergencies
.....................................
2 MACHINE DIMENSIONS 3 TECHNICAL CHARACTERISTICS
3.1
General Characteristics
4 TRANSPORTING THE MACHINE
........................
.......................
...........................
.........................
.........
.....................
...........
3
3 3 3
3 4
4
4
5 GETTING TO KNOW YOUR MACHINE..4
5.
1 Disk Head Assembly
5.2 Machine Base
5.3 Vice
5.4 Support
5.5 Stand
...................................................
Roller ...................................
.................................................
5.6 Coolant Pump
....................................
....................................
6 GETTING STARTED
.........................
...............................
4 5 5 5 5 5
6
6.1 Minimum Requirements for Housing the Machine
6.2 Anchoring the Machine
6.3 Assembly and Setup
7 RECOMMENDATIONS AND ADVICE
.............................................
......................
.........................
....
6 6 6
9
7.1 General Advise Before Using the Machine
7.2 Operator Position
7.3 Deactivating the Machine
.................................................10
............................10
................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
9 THE OPERATION CYCLE
9.1 Miter Angle
9.2 Vise Operation
9.3 Loading the Work-piece
9.4 Setting Cutting Length
9.5 Operation Cycle
..................................................11
.....................12
......................................12
.................................12
..................12
.....................13
...............................13
10 ROUTINE AND SPECIAL MAINTENANCE
........................................14
10.1 Daily Maintenance.........................14
10.2 Weekly Maintenance
10.3 Monthly Maintenance
10.4 Six-Monthly Maintenance
10.5 Oils
10.6 Oil Disposal
for Lubricating Coolant
...................................14
10.7 Special Maintenance
.....................14
....................14
..............14
...........14
.....................14
11 MATERIAL CLASSIFICATION AND CHOICE OF TOOL
11.1 Disk Structure
11.2 Choosing the Saw Blade
...................................15
................................15
...............15
11.3 Type of Disks ................................16
11.4 Choosing the Tooth Pitch
..............17
11.5 Cutting and Advance Speed
11.6 Running in the Disk
11.7 Cutting Speed Chart
.......................18
......................18
11.8 Recommended Cutting Parameters
..............................................................19
12 EXPLOSION DRAW AND PART LISTS
..................................................................20
12.1 Explosion draw A
12.2
Part List A
12.3
Part List B
12.4
Explosion draw B
12.5
WIRING DIAGRAM AND PARTS
LIST
.......................................................24
......................................21
......................................22
13 TROUBLESHOOTION
..........................20
..........................23
.........................26
13.1 Blade and cut diagnosis................26
.........17
1 SSAAFFEETTYY RREEGGUULLAATTIIOONNSS
Page 3
03/12/2014
1
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 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
use the machine without the blade guard.
uard is a self
equipment, tools or any other object.
adjusting cover that prevents contact with the blade. Never
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 MMAACCHHIINNEE DDIIMMEENNSSIIOONNSS
2
3 TTEECCHHNNIICCAALL CCHHAARRAACCTTEERRIISSTTIICCSS
Page 4
03/12/2014
3
3.1 General Characteristics
Cutting
Capacit
Main Motor
Spindle Speed
Saw Blade Maximu Cooling Pump Coolant tank
Machine Weight Machine Dimensions
(with stand) L x W x H
y
0
45
315 mm
m Vise Opening
50mm 50mm
(with stand)
100mm
90mm 80
82 x 82mm 110 x 70mm
x 80mm
2HP
(
1.5kW) /
2HP (
2.5HP (1.875kW) / 1ph / 4P
2P/ 4P 60HZ ­4P/ 8P 60HZ - 52 /
1.5kW) /
50HZ - 88 /
50HZ
1020 x 990 x 1830mm
104
- 44 / 22
120 mm
1/8 HP
5 L
175 Kg
85 x 70mm
3ph /
3ph
/ 4P/ 8P
/ 52
44 RPM 26 RPM
s
2P
RPM
RPM
/ 4P
4 TTRRAANNSSPPOORRTTIINNGG TTHHEE MMAACCHHIINNEE
4
When transporting in its
hand trolley.
5 GGEETTTTIINNGG TTOO KKNNOOWW YYOOUURR MMAACCHHIINNEE
5
5.1 Disk Head Assembly
The section of the machine composed motor, gear transfer
B A
system, disc or blade, and control handle. A. Control Lever
A long angled lever with a handle grip starting, raising, and lowering the disk head
own packaging,
use a forklift truck or
and trigger switch for
B. Transfer Case The central part of the assembly, housing the gear system and oil tank
.
5.2 Machine Base
Page 5
03/12/2014
A heavy cast iron structure that supports the miter system, vise system, and hea
d assembly.
5.3 Vice
5.4 Support Roller
5.5 Stand
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.
A Device that support longer sized material. assists stock moving through the vise.
The roller
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.
6 GGEETTTTIINNGG SSTTAARRTTEEDD
E
Page 6
03/12/2014
6
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
Use a good quality grounded electrical system.
age.
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
Environment temperature from
Relative humidity not over 90%.
6.2 Anchoring the Machine
10°C to +50°C.
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
6.3 Assembly and Setup
1
tie rods that connect through holes in t stand. Ensuring that it is sitting level.
2
he base of the
C
B
A
s motor.
D
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).
3
F
F
F
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).
4
Page 7
03/12/2014
G
Place the machine on the top of the stand.
Use an overhead hoist lift the machine unit
G G G
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
5
he stand holes.
i
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.
H
Secure the platform (H) to the stand.
Remove the oil fill transport plug from gear transfer case.
8
M
6
J
7
K
L
J
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 gear oil fill hole (J).
threaded end of the control handle into the
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
N
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).
9
Page 8
03/12/2014
P
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.
O
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.
10
11
Q
S
R
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 machine stand. Align the plate (S) holes the stand holes. Use 4, M5X6 screws to secure into place.
plate (S) next to the hole at the base of the
12
W V
T
X
Assemble the coolant tank
Insert the coolant pump (X) into the coolant tank (T). Apply an M6 washer to
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).
each of 2 M6x20 screws (U).
13
1D
1D1E1F
1G
Page 9
03/12/2014
Z
14
Y
1A
1C
X
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.
H
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.
This trough fit over
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
1B
Y
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.
14
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 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 sidewall of the machine base. This plate need not be secured with screws to allow free movement or convenient removal.
7 RREECCOOMMMMEENNDDAATTIIOONNSS AANNDD AADDVVIICCEE
7
longer one of
f 2 hex socket head screws
splash plate (1G) onto th
e rear
7.1 General Advise Before Using the Machine
Page 10
03/12/2014
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 are broken, replace the saw blade. Before carrying out any repairs of the machine, consult a technician.
kpiece. Lastly, check the disk teeth for any damage. If any of the teeth
7.2 Operator Position
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 Carefully clean and grease the machine If necessary, cover the machine.
7.4 Dismantling
General rules
lant tank
The operator should stand in front of the machine usi single hand to grip the control handle.
ng a
Before disposing of the machine, the machine should be broken down and separated into the 3 categories as follows:
Cast iron or ferrous materials 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 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
: These materials should be of single composition, without
and electronic parts (magnetic cards, etc.).
tools, as they may
Page 11
03/12/2014
guideline.
8 AADDJJUUSSTTIINNGG TTHHEE MMAACCHHIINNEE
8
differ from those described above. They are to be considered as general
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.
B
A
C
Pivot the lever (C) to unlock side to allow more r
8.3 Changing the Disk
motion. Then tighten the screw (A).
To changed the disk:
Release the mobile guard (A) by removing the hex
B
A
C
socket screw (B). Rotate the mobile guard (A) back. Place a block of wood into the vise. Lower the machine head to rest blade on the block of wood.
the cutting disk or saw
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
E
D
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.
ange of
8.4 Cleaning and Accessing the Coolant System
A
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 Replace the coolant tank in reverse order of removal.
nt to water
9 TTHHEE OOPPEERRAATTIIOONN CCYYCCLLEE
Page 12
03/12/2014
9
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 assembly.
ver (A) to release the disk head
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.
B
A
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.
A
C
B
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
9.3 Loading the Work-piece
the work-piece.
Use the vise hand-wheel to open the vise wider than the width of the work-piece. Measure and mark Place the work-piece on the flat surface in between the vise jaws.
off the length of material desired to be cut-off.
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 Use the vise hand-wheel to clamp the work-piece.
If repetitive cuts are required for material of the same width:
jaw.
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.
-
9.4 Setting Cutting Length
Page 13
03/12/2014
Setting the cutting length removes the need to repeatedly measure work-pieces for repetitive cuts of a single length.
A B C
Measure and mark off the length of material desire 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).
d to
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
D
A
Load the work-piece Clamp the work-piece Adjust the bar stop for cutting length, if necessary
E
B
Check that the main power light is ON (A). Set the speed (C). Set the cool
ant switch (B).
Grasp the control handle (G).
C
Press the trigger switch (F) to start. Pull down the control handle (G). Apply a steady and constant pressure.
F G
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
for cutting quality and for machine performance.
e
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.
Press the red emergency button (E) when there are conditions of danger of malfunctions in
Page 14
03/12/2014
general, so as to stop machine operation immediately.
0 RROOUUTTIINNEE AANNDD SSPPEECCIIAALL MMAAIINNTTEENNAANNCCEE
110
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 Grease the hinge pin for the head assembly.
10.4 Six-Monthly Maintenance
Change the oil in the reduction unit using oil type DAPHON
ee from defect.
or equivalent oil, proceeding as follows:
DN SUPER GEAR 460
by
IDEMITSU
or
Remove the connecting plug from the unscrew the control handle. Drain off the old oil from the drain hole (A)
electric box and
Pour in new oil of to the mark (B), through the hole for the control handle, keeping head in a horizontal position.
A
B
Reassemble all the parts. Check continuity o
10.5 Oils for Lubricating Coolant
f the equipotential protection circuit.
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
Machine disposal.
to
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.
1 MMAATTEERRIIAALL CCLLAASSSSIIFFIICCAATTIIOONN AANNDD CCHHOOIICCEE OOFF TTOOOOLL
Page 15
03/12/2014
111
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.
TYPES OF STEEL
Page 16
03/12/2014
Hardness Hardness BRINELL ROCKWELL R=N/mm2
----
----
----
----
----
S5
----
USE
Construction
Steels
Carbon Steels
Spring steels
Alloyed s
Hardening and tempering
and for ni
Alloyed case hardening
steels
Steel for bearings
Tool steel
Stainless steel
Copper alloys Special brass
Bronze
Cast iron
teels for
triding
11.3 Type of Disks
I D
UNI DIN
Fe360 St37 Fe430 St44 Fe510 St52 C20 CK20 C40 CK40 C50 CK50 C60 CK60
50CrV4 50CrV4
60SiCr8 60SiCr7
35CrMo4 39NiCrMo4 36NiCrMo4 41CrAlMo4 41CrAlMo7
18NiCrMo7 ----
20NiCrMo2 21NiCrMo2
100Cr6 100Cr
52NiCrMoKU
56NiCrMoV7
C100KU C100W1
X210Cr13KU X210Cr12
58SiMo8KU
X12Cr13 4001
X
5CrNi1810 4301
X8CrNi1910
X8CrNiMo1713 4401
Aluminium copper alloy G-CuAl11Fe4Ni4 UNI 5272 Special manganese/silicon brass G-CuZn36Si1Pb1 UNI5038 Phosphor bronze G-CuSn12 UNI7013/2a
Gray pig iron G25 Spheroidal graphite cast iron GS600 Malleable cast iron W40-05
34CrMo4
----
----
6
AF NOR
E24 E28 E36
XC20
XC42H1
----
XC55
50CV4
----
35CD4
39NCD4
40CADG12
20NCD7 20NCD2
100C6
----
----
Z200C12
Y60SC7
----
Z5CN18.09
----
Z6CDN17.12
F
GB
SB
---­43 50
060 A 20 060 A 40
----
060 A62
735 A 50
----
708 A 37
----
905 M 39
En 325 805 H 20 534 A 99
----
BS 1
BD2
----
----
304 C 12
----
316 S 16
BD3
AISI-SAE
52100 207 95
D6-D3
USA
1020 1040 1050 1060 6150
9262 4135 9840
4320
4315
S-1
410 304
316
The disks differ essentially in their constructive characteristics, such as: Tooth shape Tooth cutting angle Tooth shape
CHARACTERISTICS
HB HRB 116 67 360÷480 148 80 430÷560 180 88 510÷660 198
93 540÷690 198 93 700÷840 202 94 760÷900 202 94 830÷980
207 95 1140÷1330
224 98 1220÷1400 220 98 780÷930 228 99 880÷1080 232
100 930÷1130 232 100 760÷1030 224 98 690÷980
690÷980
244 102 800÷1030 212
96
710÷980
2
52 103
2
44 102 800÷103
202 94 202 94 202 94 202 94 220 98 140 77 120 69 100 56,5 212 96 232 100 222 98
820
670÷
590÷685 540÷685 490÷685
620÷
375÷440 320÷410 265÷314 245
600
420
÷10
885
685
60
0
The profile of the toothing depends on the size, shape and thickness of the section to be cut, either straight or at a 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 Large toothing is suitable for cutting medium and large solid sections or fairly thick profiled or tubular sections (over 5mm).
A
toothing
:
Normal fine toothing
n angle.
he material).
AW
toothing
Fine toothing with alternate side rake
:
B
Page 17
03/12/2014
toothing
:
BW
toothing
: Normal large toothing with or without Large toothing with alternating shaving breaking inclusion.
side rake
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 p d
R
akes vary
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
3 4 5 6 7 8 9
1,3
1,6
2,1
2,5
2,9
3,4
1,5
2
h = 0,2 mm
in accordance to material to be cut.
2,5
3
3,5
4
3,8 4,5
10
12
14
16
4,2 5,1
5,9
7,2
5 6 7 8
h = 0,3 mm
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.
To high an advance speed (=disk descent) tends to cause the disk to deviate from the ideal
Page 18
03/12/2014
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
Az Tooth advance Ng/min Number of revs per minute N/mm Ultirnate tensile stress
Z Number of teeth on th p Tooth depth
e disk a-f Flat parts of the cutting edge
Front rake Rear rake
Tube diameter of profile width
11.8 Recommended Cutting Parameters
mm/1
mm/1
mm/1
mm/1
Page 19
03/12/2014
CUTTING
ANGLES
10-20
20-40
40-60
60-90
°T mm
Vt m/1
Av
°T
mm
Vt m/1
Av
°T
mm
Vt m/1
Av
°T mm
Vt m/1
Av
Mild steel
R=950-1300 N/mm2 Austentic stainless steel
2
2
R=500-800 N/mm
Martensitic stainless Steel
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=500-800 N/mm
R=200-400 N/mm2 Alloyed brass
2
Semi-hard steel
R=500-700 N/mm2 Hard steel
R=750-950 N/mm2 Extra-hare steel
R=350-500 N/mm
R=950-1000 N/mm2 Hear-treated steel
R=200-400 N/mm2 Titanium and alloys
2
R=300-800 N/mm
Tube and beams 0.05 D
20° 18° 15° 12° 10° 12° 15° 12° 22° 20° 20° 15° 12° 16° 12° 18° 18° 15°
8° 8° 8° 6° 6° 8° 6° 8°
4 4 3 2 4 4 4 6 5 6 5 4 5 5 4 3 2
5
10°
8°
10°
8° 8°
16° 16°
8° 8° 8°
50 30 20 15 9 20 20 25 1100 200 400 400 120 600 500 50 19 35
160 130 110 60 35 50 50 100 1800 400 600 800 160 1100 700 160 130 130
6 6 4 3 6 6 6 8 7 8 7 8 6 7 4 4 3
7
45 30 20 15 9 19 19 23 1000180 350 400 110 600 400 45 18 30
150 120 110 60 33 45 45 100 1700 400 600 700 150 1100 600 150 120 110
9 8 6 4 8 8 8 12 10 11 10 8 10 10 6 5 4
10 45 25 18 14 9 18 18 22 900 160 300 350 100 550 350 45 18 30
140 110 100 50 30 45 45 90 1600 350 550 700 140 1000 600 140 110 110
12 11 9 6 11 11 11 16 12 14 12 10 12 12 10 6 5
12 40 25 17 14 8 17 17 20 800 160 250 300 90 550 350 45 17 30
130 110 50 50 28 40 40 80 1400 300 550 600 130 900 500 130 110 110
R=300-600 N/mm2 Tubes and beams 0.025 D
2
R=300-600 N/mm
°T
mm
90-110
SECTION TO BE CUT ( IN MM )
Vt m/1
Av
°T mm
110
­Vt m/1
130
Av
°T
mm
130
­Vt m/1
150
Av
RECOMMEDED LUBRIFICANTS
14 14 12 8 14 14 14 18 14 17 14 12 16 16 12 6 5
14 40 20 15 13 8 15 15 19 700 140 200 250 70 500 300 40 16 28
110 100 80 45 25 40 40 880 1300 300 500 600 110 900 500 110 100 100
16 16 14 10 16 16 16 20 16 18 16 14 18 18 14 8 6
16 35 20 14 13 7 14 14 17 600 130 150 200 60 500 300 35 16 26
100 90 70 45 25 35 35 70 1100 250 500 500 100 800 400 100 90 90
16 16 14 12 16 16 16 20 16 20 18 16 18 18 16 10 6
18 30 15 12 12 7 12 12 16 500 130 120 150 50 450 200 30 15 24 90 80 60 40 22 35 35 60 900 250 400 400 90 800 400 90 80 80
Emulsion
Cutting oil
Dry
Kerosene
Dry
Emulsion
Cutting oil
Emulsion
2 EEXXPPLLOOSSIIOONN DDRRAAWW AANNDD PPAARRTT LLIISSTTSS
Page 20
03/12/2014
112
12.1 Explosion draw A
12.2 Part List
Page 21
03/12/2014
A
Item Description
A01 Lock handle A02 Lock Nut A03 Shaft A04 Machine base A05 Roller bracket
A6-1
Hex head screw A07 Roll A08
er 1
C-
clip
1
1
1
1
1
2
S-12 2 A09 Hex socket cap screw A10 Washer A11 Hand A12 Pin A13 Bearing bushing
5
le
wheel
1
1
1 A14 Bearing A15 Bushing A16 Leading screw A17 Lock handle A18 Sliding v A19 Washer A20 Spring A21 Plate
1
1
1
ise
1
1
1 A22 Hex socket cap screw A23 Washer A24 Hex socket cap screw A25 Spring A26 Washer
1
A27 Hex socket cap screw A28 Switching handle A29 Washer
1
A30 Hex socket cap screw A31 Washer A32 Nut A33 Switching p A34
C-
A35 Blade shield
clip
late
1
1 A36 Screw A37 Plate A38 Blade cover
1 A39 Hex socket cap screw A40 Fixing flange A41 Saw blade
1
1
Size
Q'TY
M8x20
1
/16"
1
M12x25 2 5/16"
2
M8x20
2
5/16"
1
M8x20
1
1/4"
1
M6x12
1
1/4"
1
M8
M5x10
7
M12x35 1
1
1
1
Item. Description
A42 Spindle shaft A43 Worm gear A44 Lock Nut A45 Stopper A46 Vise bench
1
1
1
1
1 A47 Hex socket cap screw A48 Swing arm (base) A49 Support rod
1
1 A50 Vise clamp A51 Groove jaw A52 Small groove jaw
1
1
Size
Q'TY
M5x25
3
1
A53 Trigger switch with handle 1 A54 Nut A55 Control handle rod A56 Nut A57 Nut A58 Machine head A59 Ball bearing A60 Bal A61 Rubber sheet A62 Hex cap screw A63 Washer A64 Flange A65 Oil seal A66 Worm shaft A67 A68 Motor A69 Wire terminal clamp A70 Control w A71 Hex cap screw A72 Washer A73 Oil A74 Set screw A75 Shaft A76 Bushing A77 Hex cap screw A78 Nut A79 Lock bolt with knob
A80 A81 Upper length setting rod A82
M10
1
1
M20 M20
1 1
1
l bearing
6205zz 6301zz
1 1
1
M8x20 5/16"
4
4
1
1
1
Coupling 1
1
4
ire
pilot
M8x20 5/16" PT1/2" PT1/4"
4
4
1 2
1
1
M12x55 1 M12
1
1
Length setting rods bracket
1
1
Lower len
gth setting rod
1
1
Item
Page 22
03/12/2014
Description
A83
Nut
1
A84
Lock bolt with knob
A85
Filter plate
A86
Lift ring
A87
Drainage
A88
Washer
A89
Hex socket cap screw M8x25 2
A90
Hex socket cap screw
Size
1
1
3
1
5/16"
1
Q'TY
2
Item
Description
B01 Stand B02 Nut B03 Washer
1
B04 Support plate B05 Washer B06 Hex cap screw B07 Coolant tank B08 Hose
1
Size
Q'TY
M6 1/4"
4
4
1
1/4"
4
M6x
15 4
1
A91 Supporter A92
Washer
A93
Hex cap screw
A94
Screw M5
A95
Stop button
A96
Star
A97
Emergency switch
A98
2/4P selection switch
A99
Pump selection switch
A100
Control box panel
A101
Washer
A102
Hex socket cap screw M8x20 2
A103
Electric control box
A104
Control box button plate 1
A105
Magnetic connector
A106
Fuse set
A107
Cover plate
A108
Transformer
A109
Relay
A110
Plate
A111
Support p
1
1
t button
1
1
1
1
1
1
1
1
1
1
1
1
late
2
5/16"
2
M8x20 2
5/16"
2
4
B09 Hose clamp B10 Washer
1
1/4" B11 Hex socket cap screw M6x16 2 B12 Coolant pump B13 Connect B14 Hose clamp B15 Hose
1 B16 Hose clamp B17 Valve
1
1
ing bolt
1
1
1
B18 Wire B19 Hex c B20 Washer B21 Hex cap screw B22 Washer B23 Support plate B24 Screw B25 Cover plate B26
Collar 1
ap screw
M6x15 4 1/4" M6x15 2 1/4"
1
M5x6
1
12.3 Part List B
2
1
4
2
4
A112
Washer
A113
Hex socket cap screw M8x16 2 A114 Screw M5 A
117
Cover
2
A
118
Screw 2 A119
Oil
seal
A120
Rubber plate A121
Rubber plate A122
Holder plate A123
Anti-dust plate A124
Plate
1
5/16"
2
2
1
1 1
1
1
12.4 Explosion draw B
Page 23
03/12/2014
12.5 WIRI
Page 24
03/12/2014
NG DIAGRAM AND PARTS LIST
Motor connection
Item
Description and
name
FU1 FU2 FU3 FU4
K1
KR
Relay
TC
SB1
Emergency Stop
SB2 SB3
SB4
T
SB5
SA1
M1
Motor
M2
function
Fuses
Fuses
base
Contactor
Transformer
OFF
button
Start button
rigger
switch
Pump switch
Hi/Low speed
select switch
Coo
lant pump
Technical
30x6.2mm 250V
10A 4P
Coil 24V
It=25A 220V 2.2kw 400V 4.0kw
250VAC
23
0/24V
250V 6A
250V 6A
15A 1/2HP 125 250VAC
0.6A 125VDC 0.3 250VDC
400V,230V/ (
3ph/2P/4P
400V
,230V/ (
3ph/4P/8P
400V
/ 3ph
(
0.09kw
data
15
A
15
A
15
A
2A
5A
35VA
,400V/24V
1
250V
440V
5kw
1.5kw
1.5kw
, 230V/1PH
1/8HP
)
A
) 2HP
)2HP
Quantity
S15A
MY
-2N
AC 24V
66 , 57
HY57B
1A5
1a 30V
-5
Remarks
ICE 158 BS 5424 VDE 0660
JI3 8325
CE
CE
CSA
CE
CUS
CE
CUS
CE
CUS
CE
CUS
CE
CUS
-1
-1
Supplier
1 1 1 1 1
1
1
1
1 1
1
1
1
1
1
JENN FENG
NHD
C-12D
BETA
TAI CHUNG
KEDU
MACK
OMRON
GIKOKA
KEDU
KUOSHUAY
KUOSHUAY
V-15-
Suppliers
reference
FSB-104
ABF-221b
ABLFS-22
OSS-22
ZH-HC
KST058
KST063
12.6 WIRING DIAGRAM AND PARTS LIST
Page 25
03/12/2014
Item
Description and
name
FU1 FU2 FU3
K1
KR
Relay
TC
SB1
Emergency Stop
SB2 SB3
SB4
T
SB5
MB
function
Fuses
Fuses
base
Contactor
Transformer
OFF
button
Start button
rigger
switch
Pump switch
Protector
-5-2C
AC 24V
HY57B
1A5
OC
1a 30V
Remarks
CUS E300304
ICE 158 BS 5424 VDE 0660
JI3 8325
CUS-E115915
CE
CSA
CE
CE
CE
CUS
CE
CUS
CE
CUS
CE
CUS
CE
UL
CUL
-1
-1
Technical
Coil 24V
220V 2.2kw 400V 4.0kw
250VAC
22
250V 6A
250V 6A 2a
15A 1/2HP 125
250VAC
0.6A 125VDC 0.3A 250VDC
data 20 20
2A
10A 3
It=25A
5A
35VA
0 /
250V
30A
250V
A A
24V
P
1
Quantity
1 1 1 1
1
1
1
1 1
1
1
1
Supplier
BOSS MANN
Thining
ETI
NHD
C-18D
BETA
TAI CHUNG
KEDU
MACK
OMRON
GIKOKA
YEU SHENG
PT-66
V-15-
Suppliers
reference
FNQ-aM FNQ-aM
KTK-gG VKC-10
BMY
ABF-221b
ABLFS-22
OSS-22
M1
Motor
M2
Coolant pump
220V / 2.5 HP
1ph / 4Pole
220V / 1/8 HP
1ph / 4Pole
1
1
KAI SHEN
KAI SHEN
3 TTRROOUUBBLLEESSHHOOOOTTIIOONN
Material classification and
Page 26
03/12/2014
113
This chapter lists the probable faults a being used and suggests possible remedies for solving them.
nd malfunctions that could occur while the machine is
The first paragraph provides diagnosis for TOOLS and CUTS, the second for ELECTRICAL COMPONENTS.
13.1 Blade and cut diagnosis
FAULT
TOOTH BREAKAGE
PROBABLE CAUSE
Too fast advance Wrong cutting speed
Wrong tooth pitch
Low
quality Ineffective gripping of the part in the vise. Previously broken tooth left in the cut. Cutting resumed on a groove made previously Insuffici wrong emulsion.
Sticky accumulation of material on the disk.
ent lubricating refrigerant or
disk
.
REMEDY
Decrease advance, exerting less cutting pressure. Change disk speed and/or diameter. See chapter choice of disks speed s according to disk diameter. Choose a suitable disk. See chapter choice of disks Use a better Check the gripping of the part.
Accurately remove all the parts left in. Make the cut elsewhere, tu 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
Material
Material classification and
quality
classification
and the Table of c
.
disk.
rning the part.
quality disk.
and
utting
PREMATURE WEAR
DISK
Wrong running in of the disk .
Wrong cutting speed.
Unsuitable tooth profile.
Wrong tooth pitch.
Low quality disk. Insufficient lubricating refrigerant.
See chapter choice of disks Running in the disk. Change disk speed and / or diameter. See Chapter choice of disks speeds according to disk diameter.
Choose a suitable disk. See Chapter
Material classification and choice of
in the paragraph on Type of disks.
disks Choose a suitable disk. See Chapter 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.
Material classification and
in the paragraph on
and the Table of cutting
Material classification and
.
FAULT
in the paragraph on Type
Page 27
03/12/2014
PROBABLE CAUSE
REMEDY
CHIPPED DISK
DISK VIBRATION
RIDGES ON THE CUTTING SURFACE
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.
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 cutting dimensions. Disk diameter incorrect and/or too large.
Disk diameter incorrect and/ or too large.
Ineffective gripping of the part in the vise. Too fast advance.
Reduce the cutting pressure and/or the advance.
Change disk speed and/or diameter. See Chapter choice of disks speeds according to disk diameter. Choose a suitable disk. See Chapter choice of disks Check gripping of the part. Replace the disk with one that is more suitable and correctly sharpened. Use a better Check the percentage of water and oil in the emulsion.
Choose a suitable disk. See Chapter choice of disks Choose a suitable disk. See Chapter choice of disks o
f disks.
Check the gripping of the part.
le
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. Decrease 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.
Material classification and
and the T
Material classification and
.
quality disk.
Material classification and
.
Material classification and
the disk diamet
able of cutting
er, adapting it
Disk teeth are worn. Insufficient
Toothing does not unload shavings well.
lubricating
refrigerant.
Decrease advance, exerting less cutting pressure. Sharpen the tool. Check the 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 refrigerant.
level of the liquid in the tank.
ing
FAULT
Page 28
03/12/2014
PROBABLE CAUSE
REMEDY
CUT OFF THE STRAIGHT
BLADE STICKS IN THE CUT
Too fast advance. Ineffective gripping of the part in the vise.
Disk head off the straight. Disk sides differently sharpened. Disk thinner than the standard. Dir
Too fast advance. Low cutting speed.
Wrong tooth pitch.
Sticky accumulation of material on the disk. Insufficient
t on the gripping device.
lubricating
commercial
refrigerant.
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 surfaces.
Decrease advance, exerting less cutting pr
essure. Increase speed. Choose a See Chapter choice of disks Check the blend of lubricating coolant and choose a better 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.
.
lly clean the laying and contact
suitable disk.
Material classification and
.
quality
disk.
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use