Mega H-400GA Instruction Manual

Automatic BANDSAW

H-400GA

INSTRUCTION MANUAL

MEGA MACHINE CO., LTD.

DOC NO： H-400GA-100.U
CTRL NO：06
UPDATE： 2008/02/13
DOC VER：A1

FOREWORD
We hope that the owner of this automatic circular sawing machine will
have years of trouble-free service. The machine has been built
to the highest standards to enable fast accurate cutting to be obtained.

In order that the best results can be achieved from your MEGA circular sawing
Machine, we would ask all operators and maintenance engineers to READ
THIS MANUAL CAREFULLY BEFORE STARTING THE MACHINE.
The manual contains full instructions on installation, operation, lubrication,
maintenance and trouble-shooting.

As MEGA MACHINE COMPANY LIMITED is constantly improving the
design of its machines, there may be some instance where this book differs
somewhat from the machine with which you are concerned. So, always
quote the Serial Number of your machine, when ordering spare parts
or in correspondence relating to the machine.

MODEL :

Serial Number :

Request for service and spare parts should be made to :

ADDRESS: NO. 180, INDUSTRIAL ROAD, TAI-PING CITY, 41107 TAICHUNG,

TAIWAN R. O. C.
E-MAIL: [e-mail]; [e-mail]
URL: www.bandsaw.com.tw

TEL: [phone](PRES.) FAX:[phone]

TABLE OF CONTENTS

1. Introductory Illustrations

1.1 Principal parts ------------------------------------------------------------------------ 1

2. Specifications

2.1 Specifications ------------------------------------------------------------------------- 2

2.2 Standard Accessories----------------------------------------------------------------. 2

3. Installation

3.1 moving and lifting -------------------------------------------------------------------- 3

3.2 Foundation layout and Set-up ------------------------------------------------------- 4

3.2.1 Foundation ----------------------------------------------------------------------- 4

3.2.2 Leveling ---------------------------------------------------------------------------5

3.2.3 Cleaning and oiling---------------------------------------------------------------.6

3.2.4 Power Source Connection ------------------------------------------------------ 6

4. Operation

4.1 Control Panel ------------------------------------------------------------------------- 7

4.2 LCD Panel illustration --------------------------------------------------------------- 9

Addition 1 - Amplifying Valve-----------------------------------------------------11

4.3 Operating preparation --------------------------------------------------------------- 13

4.4 Manual Operation --------------------------------------------------------------------15

4.5 Automatic operation -----------------------------------------------------------------16

4.6 Special Operation ---------------------------------------------------------------------17

4.7 Break -In Operation ------------------------------------------------------------------17

5. Maintenance

5.1 Oiling and Lubrication ---------------------------------------------------------------18

5.2 Others ----------------------------------------------------------------------------------19

6. Trouble Shooting Guide

6.1 Sawing Problems and Solution ------------------------------------------------------21

6.2 Minor Operating Troubles and Remedies ------------------------------------------22

6.3 Error Code ---------------------------------- ------------------------------------------23

7. Reference Charts

7.1 Standard cutting Chart -------------------------------------------------------------25

7.2 Standard cutting Chart -------------------------------------------------------------26

7.3 Standard cutting Chart -------------------------------------------------------------27

Appendix

1. INTRODUCTORY ILLUSTRATIONS (全行程)

1. 1Principal Parts

1

2 SPECIFICATIONS

2.1 SPECIFICATIONS

SPECIFICATIONS MODEL H400GA

(MM)

Ø406 □400W*400H

Cutting Capacity

(IN)

Ø16 □16W*16H

Bundle Cutting

(MM)
(IN)

320W*230H
13W*9H

(MM) 32*1.06*4570

Blade Size

(IN) 1 1/4*0.042*180

(M/min) 25, 32, 42, 55, 70, 80 Variable Speed 20-80

Blade Speed

(F/min) 82, 105, 138, 180, 230, 260 Variable Speed 65-260

(KW) Blade-3.75, HYD-0.75, Coolant-0.1

Motor Output

(HP) Blade-5, HYD-1, Coolant- 1/8,

Auto Bar Feed (MM) 400

Multiple Feed Max (MM) 3600

Weight Net/Gross KG,lb 2450 / 2850 53900 / 6270

Specifications subject to change without notice for improvement and modification.

2.2 STANDARD ACCESSORIES

1. Tools with tool box .............………….……..….…....... 1 set

2. 7 ft.(2M) long roller table ...…………………..…......... 1 set

3. Band-cleaning wire brush ...………………….….......... 1 piece

4. Band saw blade .................…………………..……....... 1 piece

5. Instruction manual .............………………………........ 1 copy

2

3. INSTALLATION :

3.1 Moving and Lifting :

Unpack your machine carefully , and use a crane or forklift to set it in position.

If a crane is used to lift the machine attach the lifting cable carefully to the machine as shown in the
fig 2. If forklift is used then fig 3.
Sufficient space should be left around the machine to allow safe handling of materials , and inspection
and maintenance operation. Should there be other machinery causing vibration or dust that near your
machine, then precautions must be taken to keep your machine away from of vibration and dust.

(1) Use Crane :

Fig 2

(2) Use Forklift :

Fig 3

3

3.2 Foundation layout and set-up :

3.2.1 Foundation :

The foundation should be constructed of reinforced concrete and must be level and flat. After
the proper leveling position has been obtained , anchor the machine with anchor bolts.

The position of anchor bolts and floor dimensions are shown in fig 4:

Fig. 4

□

Contact portion with floor

○

Position of anchor bolts

※

All leveling bolts should support the weight of the machine evenly .

4

3.2.2 Leveling :

The production accuracy of all precision machinery depends on the accuracy which the machine
is installed . Manufacturing tolerance of the machine can only be guaranteed if the machine is firmly
and properly installed . Once the machine is lowered on the prepared foundation . Machinist levels
should be used alternately on the vice slide plates and the work feed table , and adjust the left-and-right
and fore-and-aft level of the machine with leveling bolt .

The fore-and-aft level should be adjusted so that the level of the rear end is approximately 10 mm
(3/8" - 1/2") higher than the level of the front end , to provide proper return of the cutting fluid , and
easy operation of car feeding .

The left-and-right level should be adjusted so that the level of the left end is approximately 3 mm (1/8")
higher than the level of the right end , to provide proper return of the cutting fluid , After the proper
leveling position has been obtained anchor the machine with anchor bolts .

CAUTION : All leveling bolts should support the weight of the machine evenly .
Leveling as fig 5 below :

FIG 5

5

3.2.3 Cleaning and oiling :

After the machine has been placed in position , thoroughly remove its rust preventive coating using
a suitable cleaning solvent and then apply a coat of machine oil . To clean the machine , Kerosene is

preferable to gasoline . It does not evaporate and level dried slushy compound on finished surfaces.
Rags are better than waste as they leave no lint or strings. The machine as received by you. has been

completely drained of all oil. Before any attempt is made to run it .... Before any motor connections

are made .... every detail of the following oiling instruction must be complied with. Refer to the oiling

chart in chapter 7.

Especially , don't forget to fill up the cutting fluid mixture. Usually , the ratio of cutting fluid to

Water should be 1:30 - 1:50. Check the sight gauge to ascertain the fluid level in the tank every day.

Transmission gear box, bar feed gear box, hydraulic oil tank should to topped up monthly. Oil

levels should be strictly observed, for it is of primary importance for proper operation and long lift .

3.2.4 Power Source Connection:

A. Power Source - This machine is equipped with 5HP main motor and 1HP hydraulic motor ,

and 1/8HP coolant motor. Connect the power supply cable to the circuit breaker(N.F.B.)
terminals. The power supply to your machine should agree with the wring voltage that is
indicated on the label attached to the electrical enclosure and main motor.

B. Earth - Be sure to connect the earth cable to the earth terminal.

C. Starting - After making the necessary wiring connections, turn the power switch on the control

panel clockwise to turn power on, depress the vice limit switch (if necessary, e.g. if there is no
stock bar clamped in the vice) and push the button to see if the saw head moves upward. If the
saw head does not rise , the hydraulic pump motor is rotating in the wrong direction. If the motor
runs in the wrong direction, turn off the power switch and disconnect the power supply cable,
Then interchange any two phase connections.

6

4. OPERATION

4.1. Control Panel

1. LCD Panel illustration

2. PILOT LAMP -- This light will comes on when the power supply is on.

3. EMERGENCY STOP -- This switch is used for emergency case to stop the machine only.

Turn this switch clockwise makes power source on. When this switch is pressed, all machine's operation
stop immediately.

4. POWER SWITCH ON -- This switch is used for turning on the power by depressing it.

5. POWER SWITCH OFF -- This switch is used for turning off the power by depressing it.

6. AUTO - MANUAL SELECTOR -- For continuous cutting , turn this selector to left "AUTO".

To individually operate each function, turn this switch to right "manual".

7. MANUAL FEED FORWARD --When this button is pressed the workpiece moves forward.

The workpiece stops advancing when the button is released.

NOTE: Turn (10) VISE SWITCH right position before depress switch (12) BLADE DRIVE to cutting.

8. MANUAL FEED BACKWARD --When this button is pressed the workpiece moves backward.

The workpiece stops moving when the button is released.
NOTE: Don't depress (7) and (8) two switches, if the workpiece are clamped by
both front and rear vises in the meantime.

9. FRONT INCHING OPEN SWITCH --

The front vise clamp the

workpiece when turn switch NO.(11) right and press button NO.(9)

1.5sec in the same time. Then the front vise hold the workpiece
after the LCD “Front vise closed” light.

10. REAR VISE SWITCH -- This switch control the rear vise jaws in manual
mode, switched to the left makes the front vise open. and switched to the right
makes the front vise clamp.

11. FRONT VISE SWITCH -- The switch control the front vise jaws in manual mode, The front

vise clamp when turn the switch to right. Then if release the switch, the switch come back to
the middle position, the vise doesn’t hold the workpiece. If operator would like to hold the
workpiece, he would follow the (9) illustration.

The front vise open little by little if the guide arm is under the front vise when the switch turn to left.
And the front vise open continuously if the guide arm is above the front vise. At last, if release the
switch, the switch come back to the middle position.

7

Light