Operating manual
Automatic Circular metal saw
CS 275 SA
CS 315 SA
CS 350 SA
Page 1
Table of Contents
1 Safety
1.1 Safety warnings (warning notes)
1.
2 Proper user
1.
3 Possible dangers caused by the circular metal saw
1.
4 Qualification of personnel
1.
5 User positions
1.
6 Safety devices
7 Individual protection gear
1.
1.
8 Safety during operation
1.
9 Safety during maintenance
1.1
0 Accident report
1.1
1 Electrical system
1.1.1 Classification of hazards
1.1.2 Other pictograms
1.4.1 Target group
1.4.2 Authorised personnel
1.6.1 Prohibition, warning and mandatory labels
1.9.1 Disconnecting the circular metal saw and making it safe
1.9.2 Using lifting equipment
1.9.3 Mechanical maintenance work
2 Technical data
3 Assembly
3.1 Extent of supply
3.
2 Storage
3.
3 Installation and assembly
3.3.1 Requirements of the installation site
3.3.2 Fasten the substructure of the circular metal saw on the floor
3.3.3 Mount the saw on the machine substructure
4 First use
3.
3.4.1 Checking
3.4.2 Direction of the saw teeth
3.4.3 Check the oil level in the worm gear
3.4.4 Fill in coolant
3.4.5 Power supply
3.4.6 Check the running direction of the saw blade
3.4.7 Check if the air entrance leak air
3.4.8 Check the function of the travel switch
4 Operation
4.1 Safety
Page 2
4.2 Control and indicating elements
4.
3 Insert workpiece
4.
4 Saw blade speed
4.4.
1 Speed change
4.4.2 Change the feeding speed
4.4.2 Select the toothing and the shape of the tooth
4.
5 Switching on the machine
4.
6 Switching off the machine
4.
7 Sawing of angles
4.
8 Cutting travel control
4.
9 Cooling
5 Maintenance
5.1 Safety
5.1.
1 Preparation
5.1.
2 Restarting
5.
2 Inspection and maintenance
5.
3 Mounting and replacing the saw blade
5.3.
1 Dimensions of sawing flange
4 Repair
5.
6 Spare parts
6.1 Explosion drawing
6.1.
1 Spare parts
2 Wiring diagram
6.
6.2.
1 Spare parts list
6.2.
2 Extra addtional spare parts list
7 Anomalies
7.1 Anomalies in the circular metal saw
Page 3
1 Safety
Glossary of symbols
• enumerations
This part of the operating manual
• explains the meaning and use of the warning references contained in the operating manual,
• explains how to use the circular metal saw properly,
• highlights the dangers that might arise for you or others if these instructions are not obeyed,
• tells you how to avoid dangers.
In addition to this operating manual please observe
• applicable laws and regulations,
• legal regulations for accident prevention,
ropean standards must be observed during installation, operation, maintenance and repair of
Eu
the circular metal saw.
European standards are not applied in the national legislation of the country of destination, the
If
specific applicable regulations of each country must be observed.
ere necessary, the required measures must be taken to comply with the specific regulation of
Wh
each country before the circular metal saw is first used.
gives additional indications
calls on you to act
ALWAYS KEEP THIS DOCUMENT CLOSE TO THE CIRCULAR METAL SAW FOR FUTURE
REFERE
NCE.
1.1 Safety warnings (warning notes)
1.1.1 Classification of hazards
We classify the safety warnings into various levels. The table below gives an overview of the
fication of symbols (pictograms) and warnings for the specific danger and its (possible)
classi
nsequences.
co
Alarm
Pictogram
DANGER!
WARNING!
CAUTION!
ATTENTION!
expres-
sion
Imminent
personnel.
Risk:
personnel.
Danger or unsafe procedure that might cause injury to
personnel or damage to property.
uation that could cause damage to the machine and
Sit
product and other types of damage.
No risk of injury to personnel.
Defini
tion/Consequences
danger that will cause serious injury or death to
A danger that might cause serious injury or death to
Page 4
Pictogram
Alarm expres-
on
si
De
finition/Consequences
INFORMATION
In the case of specific dangers, we replace the pictogram by
general danger with a warning
1.1.2 Other pictograms
Applicati
on tips and other important or useful information
and notes.
No dangerous or harmful consequences for personnel or
ects.
obj
or
injuries
to
of
han
ds,
hazardous elec-
ical voltage,
tr
rotating parts.
Caution
slide risk!
Use protective
glov
es!
Activation forbid-
den!
Use protective
boots!
Pull the mains
plug!
Wear a safety suit! Protect the envi-
Use protective
goggles!
ronment!
Use ear protec-
tion!
Page 5
1.2 Proper user
Usage
WARNING!
Impro
per use of the circular metal saw
• will endanger personnel,
• will endanger the machine and other material property of the operator,
• may affect proper operation of the machine.
The circular metal saw is designed and manufactured to be used in environments where there is
no potential danger of explosion.
The circular metal saw is designed and manufactured to saw cold metals, cast materials and
other plastic materials that are not harmful to health and do not generate dust.
The circular metal saw must not be used on wood.
pieces to be cut need to be of a shape that will allow them to be securely attached in the
The
work holder vice and ensure that the piece does not come loose when it is being sawed.
The circular metal saw must only be installed and operated in a dry and well-ventilated place.
Improper
us
If
the circular metal saw is used in any way other than as described above, modified without the
e
authorisation of supplier or operated with different process data, then it is
being used improperly.
We do not take liability for damage caused by improper use.
We would like to stress that any modifications to the construction, or technical or technological
fications that have not been authorised by supplier will also render the
modi
guarantee null and void.
is also part of proper use that
It
• the maximum values of the circular metal saw are complied with,
• the operating manual is observed,
• inspection and maintenance instructions are observed.
“Technical data“ on page 14
order to achieve the required cutting performance and the angular tolerance the correct
In
oice of the saw blade, the cutting speed and the coolant are decisive.
ch
WARNING!
Very serious injury.
is forbidden to make any modifications or alterations to the operating values of the cir-
It
cular metal saw! These could endanger personnel and cause damage to the machine.
1.3 Possible dangers caused by the circular metal saw
Page 6
The circular metal saw is state-of-the-art, but there is a residual risk, as the circular metal saw is
working
• electrical voltage and currents
• a running circular metal saw blade.
We have used construction resources and safety techniques to minimise the health risk to perso
If
a risk resulting from incorrect operation or unsuitable maintenance.
with
nnel resulting from these hazards.
the circular metal saw is used and maintained by staff who are not duly qualified, there may be
INFORMATION
All
staff involved in assembly, commissioning, operation and maintenance must
• be duly qualified,
• follow this operating manual.
In the event of improper use
• there may be a risk to the staff,
• there may be a risk to the circular metal saw and other material property,
• the proper operation of the circular metal saw may be affected.
Discon
WAR
THE CIRCULAR METAL SAW MAY ONLY BE USED WITH THE SAFETY DEVICES ACTIVA
Disconnect the circular metal saw whenever you detect a failure in the safety devices or
whe
All
safety devices.
Being
nect the circular metal saw whenever cleaning or maintenance work is being carried out.
NING!
TED.
n they are not fitted!
additional installations carried out by the operator must incorporate the prescribed
the machine operator, this will be your responsibility!
“Safety devices“ on page 8
1.4 Qualification of personnel
1.4.1 Target group
This manual is addressed to
• users,
• operators,
• maintenance staff.
The warning notes therefore refer to both operation and maintenance of the circular metal saw.
termine clearly and irrevocably who will responsible for the different activities on the machine
De
(use, maintenance and repair).
Vague or unclear assignment of responsibilities constitute a safety hazard!
Always
saw
disconnect the circular metal saw from the power supply and secure the circular metal
against restarting.
1.4.2 Authorised personnel
WARNING!
correct use and maintenance of the circular metal saw constitutes a danger for the
In
staff, objects and the environment.
authorised personnel may operate the circular metal saw!
Only
The only staff authorised to use this machine and perform maintenance on it are trained and
instructed technical staff working for the operator and manufacturer.
The operator must
Obligations
of the opera-
to
r
• train staff,
Page 7
• instruct staff regularly (at least once a year) on
- all safety standards that apply to the machine,
- operation,
- accredited technical guidelines,
• check staff‘s understand,
• document training/instruction,
• require staff to confirm participation in training/instruction by a signature,
• check whether the staff are aware of safety and of dangers in the workplace and whether
observe the operating manual.
they
The user must
Obligations
of the user
Additional
qualificatio
require-
me
• have received training in operation of the circular metal saw,
• know the function and principle of operation,
• before the machine is first used
- have read and understood the operating manual,
- be familiar with all safety devices and regulations.
For work on the following machine components there are additional requirements:
n
• Electrical components or devices: This work must only be carried out by a qualified electri-
or person working under the instructions and supervision of a qualified electrician.
nts
cian
Before carrying out work on electric components or operating units the following measures
must be taken, in the order given.
- Disconnect all poles
- Ensure that the machine cannot be turned on again
- Check that there is no voltage
1.5 User positions
The user must stand in front of the circular metal saw.
INFORMATIO
The mains plug of the circular metal saw must be freely accessible.
N
1.6 Safety devices
Use the circular metal saw only with properly functioning safety devices.
Stop the circular metal saw immediately if there is a failure in the safety device or if it is not func-
ning for any reason.
tio
is your responsibility!
It
a safety device has been activated or has failed, the circular metal saw must only be used
If
when
• the cause of the failure has been removed,
• it has been verified that there is no resulting danger for the staff or objects.
WARNING!
you bypass, remove or override a safety device in any other way, you are endangering
If
yourself and other staff working with the circular metal saw. The possible consequences
e:
ar
• damage as a result of components or parts of components flying off at high speed,
• contact with rotating parts,
Page 8
• an electrocution.
The circular metal saw includes the following safety devices:
• a protective cover on the saw blade
The saw blade of the circular
metal saw is equipped with a
protective cover. The protec-
cover covers the circula-
tive
Rear cover
tory saw blade.
WARNING!
Danger of injury! The teeth
of the saw belt are sharp.
Take great care when
removing the rear cover to
change the saw belt.
Wear protective gloves.
Illustr.: 1-1: Rear cover
Page 9
1.6.1 Prohibition, warning and mandatory labels
INFORMATION
All
warning labels must be legible.
eck them regularly.
Ch
Positions of labels on the circular metal saw:
Illustr.: 1-2: circular metal saw
Check the circular metal saw at least once per shift. Inform the person responsible immediately
of any damage, defect or change in operating function.
ck all safety devices
Che
• at the beginning of each shift (with the machine stopped),
• once a week (with the machine in operation),
• after every maintenance and repair operation.
Che
ck if the prohibition, warning and information labels and the markings on the circular metal
w
sa
• can be identified (if not, clean them),
• are complete.
1.7 Individual protection gear
For certain work individual protection gear is required. This includes:
• safety helmet,
• protective goggles or face guard,
• protective gloves,
• safety shoes with steel caps,
• ear protection.
ore starting work, make sure that the prescribed individual protection gear is available at the
Bef
rkplace.
wo
Page 10
CAUTION!
Dir
ty or contaminated personal protection gear can cause disease. Clean your personal
protection gear after each use, regularly, at least once a week.
Personal protection gear for special work
Protect your face and eyes: During all work, and specifically work during which your face and
eyes are exposed to hazards, a safety helmet with a face guard should be worn.
Use protective gloves when lifting or handling pieces with sharp edges.
Wear safety shoes when fitting, dismantling or transporting heavy components.
1.8 Safety during operation
In the description of work with and on the circular metal saw we highlight the dangers specific to
that work.
WARNING!
r to activating the circular metal saw please double-check that this will
Prio
• not endanger anybody,
• not cause any damage to property.
Avoid unsafe working practises:
• Make sure your work does not endanger anyone.
• The instructions in this manual need to be observed during assembly, handling, maintenance and repair.
• Do not work on the circular metal saw if your concentration is reduced, for example, because
you are taking medication.
• Observe the rules for preventing accidents issued by your association for the prevention of
occupational accidents and safety in the workplace or other inspection authorities.
• Stay at the circular metal saw until all rotating parts have come to a halt.
• Use prescribed protection gear. Make sure to wear a well-fitting work suit and, where necessary, a hairnet.
• Inform the inspector of any danger or failure.
Page 11
1.9 Safety during maintenance
Report and
document
any changes
Info
rm operating staff in good time of any repair and maintenance work.
port all safety-relevant changes or performance details of the circular metal saw. Document
Re
all changes, have the operating manual changed accordingly and train the machine operators.
1.9.1 Disconnecting the circular metal saw and making it safe
Unplug the circular metal saw from the mains before beginning any maintenance or repair work.
Place a warning sign on the machine.
1.9.2 Using lifting equipment
WARNING!
Us
e of unstable lifting equipment and load-suspension devices that break under load can
cause very serious injuries or even death.
Check that the lifting and load suspension gear
• is of sufficient load capacity,
• in perfect condition.
erve the preventing of accidents issued by your association for the prevention of
Obs
occupational accidents and safety in the workplace or other inspection authorities.
the loads properly.
Hold
ver walk under suspended loads!
Ne
1.9.3 Mechanical maintenance work
Remove all protection and safety devices before beginning maintenance work and re-install
them once the work has been completed. They include:
• covers,
• safety indications and warning signs,
• earth (ground) connection.
you remove protection or safety devices, refit them immediately after completing the work.
If
Check that they are working properly!
1.10 Accident report
Inform your superiors and supplier immediately in the event of
accidents, possible sources of danger and any actions which almost led to an accident (near
misses)
These near misses can have many causes.
The sooner they are notified, the faster the causes can be eliminated.
INFORMATIO
In the description of the execution of work with and on the circular metal saw, we highlight the
dangers specific to that work.
.
N
Page 12
1.11 Electrical system
Have the machine and/or the electric equipment checked regularly, and at least every six
months.
minate immediately all defects such as loose connections, defective wires, etc.
Eli
A second person must be present during work on live components, to disconnect the power in
e event of an emergency.
th
Discon
nect the circular metal saw immediately if there are any anomalies in the power supply!
“Maintenance“ on page 28, “Wiring diagram“ on page 39
Illustr.: 1-1: “Rear cover“ on page 9
Page 13
2 Technical data
380V/50Hz
6 Kg/cm
(120 l/min) 6 Kg/cm
(120 l/min) 6 Kg/cm
(120 l/min)
45°
round, max.
60mm 85mm 110mm
45° square, max.
60x60mm 70x70mm 95x95mm
Model
Code No.
Motor power
Saw blade speed
Head rotation
Clamping vice
Max. vice opening
Coolant motor
Blade max.diameter
Blade bore
Blade pin holes
Air pressure
Machine dimension
Package dimension
NW/GW
0° round, max.
0° rectangular, max.
45° rectangular, max.
70x60mm 90x70mm 110x90mm
0° square, max.
2.0KW/1.4KW (2/4 Pole)
1020x560x1460mm 1050x630x1530mm 1050x630x1550mm
890x550x1580mm 980x640x1650mm 980x640x1680mm
60x60mm 70x70mm 110x110mm
100x60mm 130x70mm 135x110mm
60mm 85mm 110mm
205/245kg 270/320kg 290/345kg
2xØ8x55mm 2xØ8xPCD55mm 2xØ8xPCD55mm
Ø275mm Ø315mm Ø350mm
Ø40mm Ø40mm Ø40mm
2
110mm 145mm 145mm
40W 40W / 400V / 50Hz 40W / 400V / 50Hz
Double Double Double
96/48 r/min 38/19 r/min 38/19 r/min
380V/50Hz
±45° ±45° ±45°
CS S275 A CS S315 A CS S350 A
1502755 1503155 1503505
1.5KW/1.1KW (4/8 Pole)
2
1.5KW/1.1KW (4/8 Pole)
380V/50Hz
2
Page 14
3 Assembly
INFORMATION
The circular metal saw comes pre-assembled.
3.1 Extent of supply
When the machine is delivered, immediately check that the circular metal saw has not been
damaged during shipping and that all components are included. Also check that no fastening
ews have come loose.
scr
INFORMATIO
the default delivery volume, no saw blade is included. If required, you can order saw blades of
In
three different toothings.
N
“Spare part list“ on page 37
3.2 Storage
ATTENTION!
Impro
per storage may cause important parts to be damaged or destroyed.
Store packed or unpacked parts only under the intended environmental conditions.
“Environmental conditions“ on page 15
nsult supplier if the circular metal saw and accessories have to
Co
be stored for a period of more than three months or under different environmental conditions to
those given here.
3.3 Installation and assembly
3.3.1 Requirements of the installation site
Organise the work area around the circular metal saw in accordance with local safety regula-
s. “Dimensions“ on page 14
tion
Ope
ration, maintenance and repair in the work area must not be hindered.
INFORMATIO
The mains plug of the circular metal saw must be freely accessible.
N
Page 15
3.3.2 Fasten the substructure of the circular metal saw on the floor
Fasten the substructure on the floor with shear connector screws M12.
Illustration: 3-1: Machine substructure
Machine
Fastening holes
substructure
Page 16
3.3.3 Mount the saw on the machine substructure
ATTENTION!
Da
nger of crushing
and overturning.
ceed with caution
Pro
during the work
described below.
CA
UTION!
Machine substruc-
ture
The circular metal saw
needs to be mounted
on the machine substructure by at least
two persons.
Hexagon socket
screw
Illustr.: 3-2: Mount the saw on the machine substructure.
Put the circular metal saw on the machine substructure.
Fasten the circular metal saw with the hexagon socket screws on the machine substructure.
Page 17
3.4 First use
WARNING!
Personnel and equipment may be endangered if the circular metal saw is first used by
expert staff.
in
We do not take liability for any damage caused by incorrect commissioning.
3.4.1 Checking
Check the following.
ATTENTION!
Danger of cutting! Proceed with caution during the work described below. Use the prescribed protection equipment.
3.4.2 Direction of the saw teeth
Check the direction of
e saw teeth. The saw
th
teeth need to be oriented in the direction of
the illustrated arrow.
Running direction
Saw blade
3.4.3 Check the oil level in the worm gear
Check the oil level in the worm gear of the circular metal saw.
“Check oil level, change gear oil.“ on page 30
Fill in gear oil, if required.
Illustration: 3-4: Running direction of saw blade
Page 18
3.4.4 Fill in coolant
CAUTION!
Da
nger of destroying the pump by dry running.
en the circular metal saw is switched on, the coolant pump is switched on.
Wh
The pump is lubricated by coolant.
Do not operate the pump without coolant.
“Filling in / Rinsing / Replacing“ on page 31
3.4.5 Power supply
Connect the mains plug of the circular metal saw with your power supply. Control the fusing
(fuse) of the power supply according to the technical indications for the power input of the circular metal saw.
INFORMATIO
For the connection, a CEE-400V-16 A connection cable needs to be connected.
CA
UTION!
ase pay attention that all 3 phases (L1, L2, L3) are connected correctly.
Ple
Most engine failure result from incorrect connection, for instance the neutral conductor
(N) is being connected to a phase.
This might lead to following results:
• The engine does get quickly very hot.
• The engine noise increases.
• The engine has no power.
N
3.4.6 Check the running direction of the saw blade
CAUTION!
the rotary field!
Mind
The saw blade is running clockwise.
eck the turning direction of the circular metal saw. The circular metal saw has to turn
Ch
direction as described in Illustration: 3-4: “Running direction of saw blade“ on
in
page 19.
If the turning direction is wrong, please exchange two of the three phases on your cable
connection or on your power supply.
Make sure that the turning direction of any other power supply is not wrong. “Qualifikation des Personals“ on page 8
4.7 Check if the air entrance leak air
3.
4.8 Check the function of the travel switch
3.
Push the travel switch, check if
the action is OK.
Page 19
4 Operation
4.1 Safety
Use the circular metal saw only under the following conditions:
• The circular metal saw is in proper working order.
• The circular metal saw is used as prescribed.
• The operating manual is followed.
• All safety devices are installed and activated.
Any anomalies should be eliminated immediately. Stop the machine immediately in the event of
any abnormality in operation and make sure it cannot be started up accidentally or without
authorisation.
tify the person responsible immediately of any modification.
No
“Safety during operation“ on page 11
4.2 Control and indicating elements
Machine vice
Locking lever cutting angle
Step switch
w blade speed
sa
Oil
level worm gear
Page 20
Foot switch
4.3 Insert workpiece
The machine vice serves
as clamping device of
e workpiece.
th
machine vice con-
The
ts of
sis
• the working table,
• the clamping jaws,
• the hand wheel.
The clamping jaws at the
ont and back are
fr
moved simultaneously,
way the machine
this
vice will clamp the clamp
parts centrically.
Insert the workpiece
needs to be
which
into the
sawed
chine vice.
ma
ATTENTION!
nger of overturning of the
Da
circular metal saw if the
chine substructure had
ma
not been fixed to the floor.
pport long workpieces
Su
before pushing the piece to
be cut into the machine vice.
Clamping jaws
Workpiece
Hand
wheel
Ma
Illustration: 4-2: Machine vice
Workpiece
terial stand
Turn the hand wheel to the
ght until the workpiece is
ri
clamped.
firmly
CA
UTION!
Make sure if the workpiece is
really firmly clamped.
Illustration: 4-3: Machine vice
Workpiece
Hand wheel
Illustration: 4-4: Hand wheel
Clamping cylinder,clam the workpiece
Page 21
4.4 Saw blade speed
4.4.1 Speed change
A speed change of the saw
blade is performed by switch-
over with the step switch
ing
on the control panel.
There are two speed levels
available which allow a wide
range of materials allowed for
sawing
• Level 1 = 19
• Level 2 = 38 m/min
4.4.2 Change the feeding speed
.
m/min
Control panel
Step switch
Illustration: 4-5: Step switch saw blade speed
4.4.3 Select the toothing and the shape of the tooth
When sawing with the circular metal saw, make sure to select the correct saw blade or the correct toothing of the saw blade.
With the help of the listed table (illustr. 5-6) you can determine the toothing for the material
ch you want to saw by yourself.
whi
N!
Page 22
CAUTIO
the toothing is too small and the cutting length is too large, the chipping material can not be
If
taken up by the gap between the tooth.
In case of large toothing, the saw tooth starts pecking; this might cause the teeth to break.
Change the feeding speed by valve
Toothing
Massive material
Profile material
Illustration: 4-6: Table for toothing
Example:
Profile material wall thickness 3 mm = toothing 10
Massive material diameter 40 mm = toothing 12
Page 23
4.5 Switching on the machine
Connect the mains plug with the power supply.
Select speed level 1 or 2.
air entrance start foot switch
4.6 Switching off the machine
Page 24
4.7 Sawing of angles
The circular metal saw can be turned from -45° to 45° in order to allow angular saw cuts.
Angle scale
Locking lever cutting angle
Illustration: 4-9: Setting of angle cut
CAUTION!
Make sure that the saw is clean and free of chips in the slewing area before adjusting it.
Loosen the locking lever.
Turn the saw to the required cutting position with the help of the angle scale.
Retighten the locking lever.
Move the locking lever to
right in order to
the
release the bearing
ock.
bl
Adjust the saw to the
required position with the
help of the angle scale.
Move the locking lever to
left in order to rec-
the
mp the bearing block.
la
4.8 Cutting travel control
Locking lever
travel control
cutting travel control
Page 25
4.9 Cooling
ATTENTION!
Damage to the pump in the event of dry running.
en the circular metal saw is switched on the coolant pump is switched on.
Wh
The pump is lubricated by the coolant. Do not start up the pump without coolant.
Turn the dosing stop valve in direction of the coolant hose until the coolant penetrates.
the turning move high temperatures are generated at the lip of the tool by the occurring fric-
By
tion heat.
cooling with an appropriate coolant/lubricant agent you will achieve better working results
By
and longer tool life of the saw blade.
Coolant pump
olant tank
Co
Fill
ing quantity about
8 litres
Page 26
Dosing stop valve
(Flow blocked)
Coolant hose
Illustration: 4-11: Coolant appliance
INFORMATION
a water-soluble and non-pollutant emulsion as a cooling agent. This can be acquired from
Use
authorised distributors.
sure that the cooling agent is properly retrieved.
Make
Respect the environment when disposing of any lubricants and cooling agents.
Follow the manufacturer‘s disposal instructions.
5 Maintenance
In this chapter you will find important information about
• inspection,
• maintenance,
• repair.
The diagram below shows which of these headings each task falls under.
MAINTENANCE
Inspection Maintenance
Measuring Rough cleaning Repairs
Testing Fine cleaning Replacing
Conserving
Lubricating
Completing
Re
placing
Readjusting
Illustration: 5-1: Maintenance – definition according to DIN 31051
Repair
Adjusting
ATTENTION!
perly-performed regular maintenance is an essential prerequisite for
Pro
• safe operation,
• fault-free operation,
• long service life of the machine and
• the quality of the products you manufacture.
tallations and equipment from other manufacturers must also be in optimum condition.
Ins
ENVIRONMEN
TAL PROTECTION
Make sure that when working on the worm gear and on the coolant tank
• collection tanks are used where the collecting capacity is appropriate for the quantity
of liquids which needs to be collected.
• any spilt liquids and oils are not spilt on the ground.
an up any spilt liquid or oils immediately using proper oil-absorption methods and dispose of
Cle
em in accordance with current legal requirements on the environment.
th
Cleaning up spillages
Do not re-introduce liquids spilt outside the system during repair or as result of leakage from the
reserve tank: collect them in a special vessel to be disposed of.
Disposal
Never dump oil or other pollutant substances in water inlets, rivers or channels.
Page 27
Used oils must be delivered to a collection centre. Consult your superior if you do not know
where the collection centre is.
5.1 Safety
WARNING!
The consequences of incorrect maintenance and repair work may include:
• Very serious injury to staff working on the machine,
• damage to the machine.
qualified staff should carry out maintenance and repair work on the machine.
Only
5.1.1 Preparation
WARNING!
Only
carry out work on the machine if it has been unplugged from the mains power sup-
ply.
tach a warning label.
At
5.1.2 Restarting
Before restarting, run a safety check.
WARNING!
Prio
r to activating the machine please double-check that this will
• not endanger anybody,
• not damage the machine.
Page 28
5.2 Inspection and maintenance
The type and extent of wear depends to a large extent on individual usage and service condi-
ns. For this reason, all the intervals are only valid for the authorised conditions.
tio
INTE
RVAL WHERE? WHAT? HOW?
• Replace the lubricating oil in the worm gear.
• Regularly check the oil level on the sight glass.
• The oil level has to reach at least the middle of the sight glass.
.
,
l
le
io raeg egnahc
ve
l
lio k
ceh
C
every six
ths
mon
r
a
e
g
mro
W
Charging hole
Worm gear
Oil
sight glass
every six
mon
ths
as required
Illustration: 5-2: Oil level worm gear
INFORMATION
e filling quantity amounts to about 0.5 litres
Th
Type of the gear oil, “Operating material“ on page 15
m
e
ts
y
s
l
aci
rt
ce
l
E
enihcaM
Check the electrical devices / components of the circular
tal saw .
me
kce
h
C
eni
hcam
e
ht
g
n
i
naelC
“Qualification of personnel“ on page 7
Clean the machine with an appropriate cloth and provide
rust protection with a conserving type of oil.
“Operating material“ on page 15
Page 29
INTERVAL WHERE? WHAT? HOW?
Regularly remove the chips which are accumulating below
as required
as required
eciv
ec
iV
k
col
b
g
ni
r
a
eb
r
o
b
rA
eht
gninaelC
etacirbuL
the clamping jaws.
To do so, use a thin, flat brush.
• Lubricate the arbor of the bearing block
Illustration: 5-3: Bearing block
CA
UTION!
ver clean the vice with compressed air.
Ne
Lubricating nipple
bor
Ar
aring block
Be
as required
every six
mon
ths
according to
wear
eciv
en
i
hc
a
M
m
e
ts
ys
t
na
l
oo
C
edalb waS
• Lubricate the spindle of the machine vice at the provided lubricat-
e
ld
n
i
pS
g
n
ic
a
lpe
R
/
g
n
i
sn
i
R
/
n
i
g
n
i
l
l
i
F
e
da
lb w
a
s
e
h
t
gn
i
c
a
lp
eR
ing nipples.
Type of lubricating oil, “Operating material“ on page 15
•
The coolant pump is almost maintenance-free.
• Replace the cooling agent regularly, depending on usage.
• Rinse the coolant pump when using coolants which leave residues.
• In order to exchange the coolant liquid, pump it into an appropriate collecting vessel and refill the coolant liquid.
INFORMATION
The filling quantity amounts to about 8 litres. Thus
the tank is filled about 2/3 of its filling capacity.
“Mounting and replacing the saw blade“ on page 32
Page 30
INFORMATION!
The spindle bearing is prelubricated. No lubricating is required.
5.3 Mounting and replacing the saw blade
Disconnect the circular metal saw from the electrical supply.
“Disconnecting the circular metal saw and making it safe“ on page 12
ATTENTION
Da
nger of cutting,
ease proceed care-
pl
fully when perform-
the below
ing
!
Step switch
described works. Use
the prescribed personal protective gear.
Switch the step
tch to the position
swi
Shells
0.
Disconnect the
plug.
mains
Adjust the saw to the
maximum top.
Illustration: 5-4: Mounting and replacing the saw blade
Push the shells of the protective device apart.
Loosen the socket screw M8 from the sawing spindle and remove the cutting flange.
Remove the sawing blade.
Thoroughly clean the sawing spindle and the flange.
Reassemble the
parts in reverse
uence.
seq
UTION!
CA
Please proceed carefully when performing
Cylinder screw
the below described
s.
work
Mind the turning
rection of the saw
di
ade.
bl
Check that the saw
Cutting flange
is correctly set.
Close the protective
hood again.
Saw blade
Illustration: 5-5: Mounting and replacing the saw blade
When mounting the saw blade, make sure that the saw blade is correctly positioned on the
flange of the spindle.
Page 31
5.3.1 Dimensions of sawing flange
Sawing flange
5.4 Repair
For any repair work, get assistance from an employee of supplier‘s technical
rvice or send us the circular metal saw.
se
the repairs are carried out by qualified technical staff, they must follow the indications given in
If
manual.
this
Supplier
against damage and operating anomalies resulting from failure to observe this operating manual.
For repairs, only use
g spindle
Sawin
Illustration: 5-6: Sawing flange
does not take any responsibility nor does it guarantee
Page 32
• faultless and suitable tools
• original spare parts or parts from series expressly authorised by supplier.
6 Spare parts
6.1 Explosion drawing
33
6.1.1 Spare parts
106
98
103
104
10
2
10
0
99
123
12
4
12
5
98
97
96
95
94
10
7
93
92
110
8
10
10
10
113
11
9
1
91
114
1
112
116
115
117
118
79
80
Abb.6-2: Vorderansicht - Front view
87
86
85
84
83
82
81
80
79
77
78
75
76
73
74
72
88
90
89
60
62
70
66
71
57
58
59
61
63
64
65
67
68
69
53
56
55
54
52
51
50
34
Abb.6-3: Hinteransicht - Opinion behind
42
43
41
39
38
37
44
45
46
47
49
35
48
36
34
33
32
31
30
29
21
27
20
22 23
28
Abb.6-4: Schnellspannschraubstock - Machine vice
17
18
19
24
25
26
16
14
13
1
2
3
5
7
8
4
10
40
11
6
9
12
15
Abb.6-5: Maschinenunterbau - Machine substructure
127
35
6.2 Wiring diagram
36
6.2.1 Spare parts list
.soP
Bezeichnung Designation
1 Zylinderschraube Socket-head cap screw 4 M5x10 033023001
2 Deckel Cover 1 033023002
3 Unterlegscheibe Washer 4 033023003
4 Kühlmittelschlauch Cooling agent hose 1 033023004
5 Kühlmittelschlauch Cooling agent hose 1 033023005
6 Pumpe Pump 1 033023006
7 Zylinderschraube Socket-head cap screw 4 M5x10 033023007
8 Unterlegscheibe Washer 4 033023008
9 Reduzierstück/ Schlauchklemme Reducer / Hose clip 1 033023009
10 Schaltkasten Switchbox 1 0330230010
11 Zylinderschraube Socket-head cap screw 4 M6x20 0330230011
12 Zylinderschraube Socket-head cap screw 4 M5x20 0330230012
13 PG-Verschraubung PG-screw connection 5 0330230013
14 Maschinenunterbau Machine stand 1 0330230014
15 Kühlmittelbehälter Coolant tank 1 0330230015
16 Reduzierstück Reducer 1 0330230016
17 Grundplatte Baseplate 1 0330230017
18 Ring Ring 1 0330230018
19 Gewindestück Threaded part 1 0330230019
20 Spannstange Linkage 1 0330230020
21 Griff Handle 1 0330230021
22 Unterlegscheibe Washer 2 0330230022
23 Spannmutter Tightening nut 1 0330230023
24 Mutter Nut 3 0330230024
25 Zylinderschraube Socket-head cap screw 3 M8x60 0330230025
26 Sechskantschraube Hexagon head screw 2 M12x30 0330230026
27 Schloß Lock 1 0330230027
28 Tür Door 1 0330230028
29 Mutter Nut 1 0330230029
30 Abdeckung Cover 1 0330230030
31 Nabe Hub 1 0330230031
32 Spannstange Linkage 4 0330230032
33 Griff Handle 4 0330230033
34 Passfeder Key 1 6x6 0330230034
35 Gewindewelle Threaded shaft 1 0330230035
36 Führungswelle Guide shaft 2 0330230036
37 Gewindestift Threaded pin 2 M8x10 0330230037
38 Unterteil Lower part 1 0330230038
39 Zylinderstift Cylindrical pin 2 10x30 0330230039
40 Motor Kühlmittelpumpe Motor cooling pump 1 03302300M2
41 Spannbacken Chuck jaws 2 0330230041
42 Zylinderschraube Socket-head cap screw 2 M10x25S 0330230042
43 Stützblock Supporting block 1 0330230043
44 Schutzblech Shield 1 0330230044
45 Mutter Nut 4 M10 0330230045
46 Spannbacken Chuck jaws 2 0330230046
47 Zylinderschraube Socket-head cap screw 4 M10x30 0330230047
48 Klemmbacke Clamping jaw 0330230048
49 Schmiernippel Lubrication fitting 2 0330230049
50 Arm Arm 1 0330230050
51 Sechskantschraube Hexagon head screw 2 M10x25 0330230051
52 Unterlegscheibe Washer 2 0330230052
53 Sägemotor Sawing motor 1 1,5 KW 03302300M1
54 PG-Verschraubung PG-screw connection 2 0330230054
55 Unterlegscheibe Washer 4 0330230055
56 Zylinderschraube Socket-head cap screw 4 M5x10 0330230056
57 Stufenschalter Step switch 1 03302300QS
58 Anschluss Connection 1 0330230058
59 Dichtung Seal 1 0330230059
60 Mutter Nut 1 0330230060
61 Zahnrad Gear wheel 1 Z=17; m=2 0330230061
62 Zylinderschraube Socket-head cap screw 8 M10x20 0330230062
63 Schmiernippel Lubrication fitting 2 0330230063
64 Montagewinkel Assembly angle 1 0330230064
65 Sechskantschraube Hexagon head screw 4 M10x25 0330230065
66 Unterlegscheibe Washer 4 0330230066
67 Feder Spring 2 0330230067
e Grösse Artikelnummer
Meng
Qty. Size Item no.
37
.so
Bezeichnung Designation
P
68 Sechskantschraube Hexagon head screw 2 M10x25 0330230068
69 Arm Arm 1 0330230069
70 Unterlegscheibe Washer 2 0330230070
71 Mutter Nut 1 0330230071
72 Zahnrad Gear wheel 1 Z=31; m=2 0330230072
73 Abstandsring Space ring 1 0330230073
74 Zylinderschraube Socket-head cap screw 4 M10x20 0330230074
75 Sicherungsring Snap ring 1 0330230075
76 Lager Bearing 1 6206 0330230076
77 Ring Ring 1 0330230077
78 Axiallager Axial-thrust bearing 1 81106TN 0330230078
79 Welle Shaft 1 0330230079
80 Skalenteilung Scale 1 0330230080
81 Paßfeder Key 1 10x8x25 0330230081
82 Schneckenwelle Worm shaft 1 0330230082
83 Nadellager Needle bearing 1 BK3026 0330230083
84 Sägekopfgehäuse Sawing head housing 1 0330230084
85 Sichtglas Sight glass 1 0330230085
86 Zylinderschraube Socket-head cap screw 4 M5x10 0330230086
87 Typenschild Identification plate 1 0330230087
88 Stopfen Plug 2 0330230088
89 Rändelmutter Knurled nut 1 0330230089
90 Zylinderschraube Socket-head cap screw 1 M10x60 0330230090
91 Dichtung Seal 1 45x65x14 0330230091
92 Sägespindel Sawing spindle 1 0330230092
93 Sägeblatt Saw blade 1 HSS 4 ZpZ 3357454
93 Sägeblatt Saw blade 1 HSS 6 ZpZ 3357456
93 Sägeblatt Saw blade 1 HSS 8 ZpZ 3357458
94 Zylinderstift Cylindrical pin 1 8x20 0330230094
95 Sägeflansch Sawing flange 1 0330230095
96 Zylinderschraube Socket-head cap screw 1 M10x25 0330230096
97 Gelenkhaube Joint hood 1 0330230097
98 Bolzen Bolt 4 0330230098
99 Kupplungsstange Coupling rod 1 0330230099
0 Zentrierhülse Centering case 1 03302300100
10
1 Zylinderschraube Socket-head cap screw 3 M10x60 03302300101
10
2 Absperrhahn Shut-off valve 1 03302300102
10
10
3 Ring Ring 1 03302300103
4 Kupplungsstange Coupling rod 1 03302300104
10
5 Stehbolzen Bolt 1 03302300105
10
6 Kupplungsstange Coupling rod 1 03302300106
10
7 Abstandscheibe Shim 1 03302300107
10
8 Kupplungsstange Coupling rod 1 03302300108
10
10
9 Sicherungsring Snap ring 5 10x0,5 03302300109
110 Schutzhaube Protection hood 1 03302300110
1 Lagergehäuse Bearing cover 1 03302300111
11
112 Sicherungsring Snap ring 1 78x2,5 03302300112
113 Lager Bearing 1 6207 03302300113
114 O-Ring O ring 1 75x2,7 03302300114
115 Buchse Socket 1 03302300115
116 Schneckenrad Worm gear 1 03302300116
117 Sicherungsring Snap ring 1 32x1,5 03302300117
118 Nadellager Needle bearing 1 BK3026 03302300118
3 Sicherungsring Snap ring 1 32x1,5 03302300123
12
4 Buchse Socket 1 03302300124
12
5 Scheibe Shim 1 03302300125
12
6 O-Ring O-ring 1 40x3 03302300126
12
127 Foot switch
M1 Sägemotor Sawing motor 1 1,5 KW 03302300M1
M2 Motor Kühlmittelpumpe Motor cooling pump 1 0,4 KW 03302300M2
QS Stufenschalter Step switch 1 03302300QS
KM Motorschütz Motor contactor 1 03302300KM
TC Transformator Transformer 1 03302300TC
SB Drucktaster Ein Push button on 1 03302300SB
Menge Grösse Artikelnummer
Qty. Size Item no.
1
38
6.2.2 Extra addtional spare parts list
Pos. Designation Size Qty.
1 Socket hexagon head screw M8X25 2
2 Plain washer Φ8 2
3 Connect base 2
4 Connect plate 2
5 Shaft 2
6 Hexagon nut M16 1
7 Feed cylinder Φ57 1
8 Cylinder adjustment Φ69 1
9 Socket hexagon head screw M8X25 4
10 Bracket(one) 1
11 Bracket(two) 1
12 Bar 1
13 Socket hexagon head screw M10X30 4
14 Socket hexagon head screw M10X30 4
15 Stand 1
16 Jaw support 1
17 Protect guard 1
18 Clamping cylinder 1
19 Limited nut 1
20 Lead screw 1
39
7 Anomalies
7.1 Anomalies in the circular metal saw
ANORMALTY
Saw motor overloaded
Engine is not running
Short life of saw belt
(Teeth blunt)
Breaking of teeth
CAUSE
/
POSSIBLE EFFECTS
• Suction of motor cooling air hind
dere
• Motor not correctly fixed
• Power unit for saw belt not cor-
rectly fixed
• Engine connected incorrectly
• Relay or engine defective
• Step switch is switched to position
0/ OFF
• Thermal protection of the engine is
defective
• Quality of saw belt not suitable for
this material
• An incorrect toothing causes
kage of teeth (the broken
brea
tooth in the workpiece blunts the
other teeth)
• Missing cooling
• Cutting speed too high
• Chip space in the saw belt full,
toothing incorrect
SOLUTIO
• Check and clean
• Requires technical service! Have
the machine repaired in the worksho
• Request help of electrical specialists
• Saw belt with higher quality
• Select correct toothing
• Use coolant system
• Reduce cutting speed
• Use saw belt with different toothing or reduce feed
N
p
Twisted cut (saw belt devi-
)
ating
Saw excessively jerks or
breaks
Cut not rectangular, but
parallel
Cooling does not work
• Saw belt blunt
• Cutting pressure too high
• Saw belt defective (irregular set)
• Cutting speeds too high
• Teeth too blunt or too small gaps
be
tween the teeth
• Saw jerks as chips remain in the
ga
ps of the saw blade
• The saw is installed reverse to the
turning direction
• Material not resting on both vice
rail
s
• Vice jaws not adjusted to 90°
• The valve on the sawing hood is
close
d
• The pump is not connected
• Pump defective
• Coolant tank empty
• Suction tube of the coolant pump
is blocked
• Wrong turning direction of the
pum
p
• Replace
• Reduce
• Replace
• Have saw grinded and the gaps
between the teeth polished
• Turn round the saw and check the
tee
th
• Support material properly
• Correctly adjust the circular metal
saw
Page 40
Loading...