Operating Instructions & Parts Manual. 10 Automatic Horizontal Band Saw. Model

Transcription

1 Operating Instructions & Parts Manual EN 10 Automatic Horizontal Band Saw Model

2 PLEASE READ AND SAVE THESE INSTRUCTIONS. READ CAREFULLY BEFORE ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE OR MAINTAIN THE PRODUCT DESCRIBED. PROTECT YOURSELF AND OTHERS BY OBSERVING ALL SAFETY INFORMATION. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE! RETAIN INSTRUCTIONS FOR FUTURE REFERENCE. PLEASE REFER TO BACK COVER FOR INFORMATION REGARDING PALMGREN S WARRANTY AND OTHER IMPORTANT INFORMATION. Model #: Serial #: Purch. Date: 2017 Palmgren / a C.H. Hanson Brand All Rights Reserved

3 GETTING STARTED Save this manual You will need this manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts lists and diagrams. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep this manual and invoice in a safe and dry place for future reference. Structural requirements Make sure all supporting structures and load attaching devices are strong enough to hold intended loads. If in doubt, consult a qualified structural engineer. Electrical requirements The power supply to the Model Fully Automatic Band Saw needs to be 220V DC, 9 amps, 60 HZ. The control circuit voltage for this machine is 24V and 110V. Tools needed Standard professional mechanic s hand tool set (i.e. hammer, screwdrivers, wrenches, socket wrenches, pliers, etc.). UNPACKING When unpacking, check to make sure all parts listed below are included. If any parts are missing or broken, please contact your local retailer. IMPORTANT: Many unpainted steel surfaces have been coated with a protectant. To ensure proper fit and operation, remove coating. Coating can be easily removed with mild solvents, such as mineral spirits, and a soft cloth. Avoid getting solution on paint or any of the rubber/plastic parts. Solvents may deteriorate these finishes. Use soap and water on paint, plastic or rubber components. After cleaning, cover all exposed surfaces with a light coating of oil. Never use highly volatile solvents. Nonflammable solvents are recommended to avoid possible fire hazard. Contents of Model Band Saw Leveling pads (6) Set of open ended wrenches Crescent adjustable wrench (1) Set of hex wrenches Flathead screwdriver (1) Phillips screwdriver (1) Grease gun (1) Unpack Remove all the over packing materials, but leave unit attached to its pallet. Do not discard packing materials until after the machine has been inspected for damage and completeness. Locate loose parts and set them aside. Inspect After unpacking the unit, carefully inspect for any damage that may have occurred during transit. Check for loose, missing, or damaged parts. Shipping damage claims must be filed with the carrier. This machine and its accessories should be visually inspected before use, in addition to regular periodic maintenance inspections. Be sure that the voltage labeled on the unit matches your power supply. SAFETY RULES For you own safety, read all of the instructions and precautions before operating the tool. Always disconnect the machine from its power source before changing blades or carrying out any maintenance procedure even in the case of irregular machine operation. PROPOSITION 65 WARNING: Some dust created by using power tools contain chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: Lead from lead-based paints Crystalline silica from bricks and cement and other masonry products Arsenic and chromium from chemically-treated lumber Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area and work with approved safety equipment. Always wear OSHA/NIOSH approved, properly fitting face mask or respirator when using such tools. Always follow proper operating procedures as defined in this manual even if you are familiar with the use of this or similar tools. Remember that being careless for even a fraction of a second can result in severe personal injury. Keep hands and body parts away from the blade and other moving parts. Never open the blade cover when the machine is running. Read all of these instructions before using your tool Dress properly. Do not wear loose clothing, shirts with sleeves that are too long, gloves that are too big, jewelry or chains as they can be caught in moving parts. Protective, electrically non-conductive clothes and non-skid footwear are recommended when working. Wear restrictive hair covering to contain long hair. Use eye and ear protection. Always wear ANSI approved impact safety goggles. 3 GETTING STARTED SAFETY / SPECIFICATIONS ASSEMBLY / INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE / REPAIR

4 MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION ASSEMBLY / INSTALLATION SAFETY / SPECIFICATIONS GETTING STARTED SAFETY RULES (CONTINUED) Stay alert. Watch what you are doing, use common sense. Do not operate any tool when you are tired. Guard against electrical shock. Prevent body contact with grounded surface such as pipes, radiators, ranges and refrigerator enclosures. Do not operate tool if under the influence of alcohol or drugs. Read warning labels on prescriptions to determine if your judgement or reflexes will be impaired. If there is any doubt, do not operate the tool. Preparing the work area for your job Keep work area clean and free of equipment, tools or other objects. Cluttered areas invite injuries. Observe work area conditions. Do not use machines or power tools in damp or wet locations. Do not expose to rain. Keep work areas well lighted. Do not use electrically powered tools in the presence of flammable gases or liquids. Keep children away. Children must never be allowed in the work area. Do not let them handle machines, tools or extension cords. All internal operations, maintenance, or repairs must be performed in a well-lit area Maintaining your tool Maintain this machine with care. Use a clean sharp cutting blade for better and safer performance. Follow instructions for lubricating and changing accessories. Inspect the power supply cables periodically and if damaged, have them repaired by an authorized technician. The machine must be completely disconnected from its power source before any maintenance or service is performed. Follow OSHA lock-out, tag-out procedures to prevent accidental machine starts. Immediately replace any damaged or obscured warning labels that are attached to the machine. Replacement parts and accessories. When servicing, use only identical replacement parts. Use of any other parts will void the warranty. Only use accessories intended for use with this tool. Approved accessories are available from your local retailer. Maintenance. For your safety, service and maintenance should be performed by a qualified technician. Know how to use your tool The blade must not move when the saw frame is in suspended mode (or raised). Only the blade section used for cutting can be exposed. Use the blade guides to adjust the blade guards. Never use the machine without its guards in place and working properly. Never put your hands or arms near the cutting area while the machine is operating. Do not move the machine while it is cutting. 4 Keep the area free of equipment, tools, or any other objects. Perform only one operation at a time. Never have several objects in your hands at the same time. Keep your hands as clean as possible. Do not force tool. It will do the job better and more safely at the rate for which it was intended. Do not use inappropriate attachments in an attempt to exceed the tool capacity. Use the right tool for the job. Do not attempt to force a small tool or attachment to do the work of a large industrial tool. There are certain applications for which this tool was designed. Do not modify this tool and do not use this tool for a purpose for which it was not intended. Do not overreach. Keep proper footing and balance at all times. Do not reach over or across machines while in operation. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches are removed from the tool or machine work surface before attaching it to a power supply. Avoid unintentional starting. Be sure the switch is in the OFF position when not in use and before attaching the machine to a power supply. Check for damaged parts. Before using any tool, any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment and binding of moving parts; any broken parts or mounting pieces should be properly repaired or replaced by a qualified technician. Do not use the tool if any switch does not turn ON and OFF properly. The warnings, cautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. SPECIFICATIONS Model Fully Automatic Band Saw Main Motor Hydraulic Motor Coolant Motor 3 HP 1 HP 1/6 HP Cutting Capacity Rectangle 9-13/16" x 11-13/16" Cutting Capacity Round 9-13/16 Blade Length 138.2" Blade Width 1" Blade Thickness 0.035" Blade Speed Hydraulic Tank (gal.) 7.92 Coolant Tank (gal.) Allowable Loading Capacity 3,305 (lbs.) Roller Stand Loading Capacity 4,410 (lbs.) FPM

5 SPECIFICATIONS (CONTINUED) Bundle Cutting (W x H) 6" to 9-3/4" x 4" to 5" Cut off Length 0.39" Cutting Amount Setting Feeding Stroke 15-3/4" Minimum Material 1-1/4" Table Height 29-1/2" Dimensions (L x W x H) 87" x 90-5/32" x 74-13/32" Weight (lbs) 3,725 ASSEMBLY/INSTALLATION In the event of incorrect operation or dangerous conditions, the machine may be stopped immediately by pressing the red emergency shut off button. The casual or voluntary removal of the flywheel covers causes a micro-switch activation that automatically stops all machine functions. NOTE: Resetting of machine operation after each emergency stop requires specific restart button. Machine dimensions Environmental and installation requirements The electrical supply must comply with the machine s motor requirements. Environment temperature should fall within 14 F to +122 F. Relative humidity cannot be over 90%. Securing the machine to the foundation Position the machine on a flat and level foundation of reinforced concrete. The foundation must be strong enough to support the weight of the machine. Anchor the machine to the foundation with anchor bolts. Maintain a minimum distance of 32 from the rear of the machine to the wall. Position the anchors using screws and expansion plugs or tie rods sunk in cement. Leveling the machine The operating accuracy of all precision machinery depends on the installation of the machine. Manufacturing tolerances can only be guaranteed if the machine is installed properly onto a solid foundation. Once the machine is lowered on the prepared foundation, machinist levels should be used alternately on the vise slide plates and work feed table. Adjust the left to right and front to back leveling of the machine with leveling bolts. All leveling bolts should support the machine evenly. Machine deactivation If the machine is to be out of use for a long period of time, the following procedures are highly recommended: Disconnect the machine from the power supply. Loosen the tension on the blade. Empty the coolant tank. Carefully clean and grease the machine. Cover the machine. OPERATION The operation of any power tool can result in foreign objects being thrown into the eyes, which can result in severe eye damage. Always wear safety goggles complying with United States ANSI Z87.1. Keep your hands away from all cutting edges and moving parts. Never reach under the saw. The blade is exposed in these areas and the guards cannot protect your body there. The automatic vise clamps on this machine exert great pressure on the clamped workpieces when they are activated. Use extreme caution when placing, positioning and clamping stock with the vise clamps. In case of an emergency situation Push the emergency shut off button down to stop all functions. To release the emergency shut off button rotate the mushroom shaped button clockwise. The button will pop up and the cutting cycle can be restarted. 5 GETTING STARTED SAFETY / SPECIFICATIONS ASSEMBLY / INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE / REPAIR

6 MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION ASSEMBLY / INSTALLATION SAFETY / SPECIFICATIONS GETTING STARTED OPERATION - DESCRIPTION OF MACHINE PARTS AND FUNCTIONS The machine control panel A. Control Panel (Interface Control Screen) Press the hydraulic start button B to start. B. Hydraulic Pump Start Switch Press to start the pump and button will light. C. Emergency Stop Button Stops and resets the machine parameters. Rotate the button to release the button and restart the machine. D. Auto/Manual Switch This switch changes mode selection between automatic and manual operation. Use Manual Mode for single cut operations and Auto Mode for multiple cutting cycles. E. Operation Start Button Starts the cutting operation cycle. F. Bow Up Button and Stop Cycle Cutting Press to raise the saw bow. The button also stops the machine s operation without resetting. G. Bow Down Button Press to lower the saw bow. H. Bench Vise Close Button Press to approach or clamp the workpiece. I. Bench Vise Open Button Press and hold the button to adjust the vise to a desired width. The button opens one full length when saw bow is at the safe height. When saw bow is not at the safe height, the vise will open approx. 3/16 when the button pressed but not held down. J. Shuttle Vise Close Button Press to approach or clamp the Shuttle Vise on the workpieces. 6 A C R D O P L M B E F G K I H J K. Shuttle Vise Open Button Press and hold the button to adjust the vise to a desired length. The button opens one full length when saw bow is at the safe height. When saw bow is not at the safe height, the vise will open approx. 3/16 when the button pressed but not held down. L. Shuttle Vise Forward Button Press to advance the vise or workpiece. M. Shuttle Vise Backward Button Press to retreat the vise or workpiece. O. Work Light Switch Press to light the Work Light. The button light illuminate. Press again the Work Light will go off. P. Coolant Switch Press to start the coolant pump and begin coolant flow. The button will illuminate. Press again the coolant pump will go off. R. Power indicator light. PRESSURE AND DOWN FEED CONTROL X. Cutting Pressure Knob This knob sets the rate for the cutting pressure for different materials. Y. Bow Down Feed Knob The knob sets cutting advance rate. NOTE: There are five indicator lights on the control panel. They correspond to the vise and bow rise up or down operation. One is for shuttle vise movement and two are for vise clamping. They become illuminated when material is properly clamped in their respective vises or when the shuttle vise has reached its forward limit position. The saw bow will not start if the clamping indicator lights are not lit. X Y

7 The saw bow The saw bow consists of the drive members (gear motor or variable speed motor, flywheels), tightening and guide (blade tightening slide, blade guide blocks) of tool and cutting angle adjustment. The vise system The automatic vise clamps on this machine exert great pressure on the clamped workpieces when they are activated. Use extreme caution when placing, positioning and clamping stock with the vise clamps. 1A This machine utilizes the function of two vises (1A) to perform the automatic feed operation. The vise system consists of a slotted bench vise and shuttle vise for three point clamping and feeding of the work material. The shuttle vise has a two-sided hydraulic system that allows it to clamp and feed irregular pieces without binding. The approach sensor 2A The approach sensor (2A) reduces operation cycle time by allowing the saw bow to approach the work piece quickly and then slow to the cutting rate just before blade touches the work piece. The nesting clamps (optional) Nestling clamps are used for bundle cutting operations. They press down the material allowing the grouping of many small diameter workpieces. This provides efficiency for cutting many small, equally sized pieces. These clamps are hydraulically operated and are connecting to the bench vise and shuttle vises. Blade breakage sensor 3A The Model Automatic Band Saw is equipped with automatic power shut-off safety sensor (3A) to help prevent machine damage when a blade has been broken. This blade breakage sensor determines the movement of the blade flywheel. If the blade is broken or the blade tension is too loose the flywheel will not move. The sensor recognizes the lack of movement and shuts down the machine. The base The base is the structure supporting the saw bow (the bow pivot point and respective blocking system), the vises, rollers, feeding and coolant systems. 7 GETTING STARTED SAFETY / SPECIFICATIONS ASSEMBLY / INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE / REPAIR

8 MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION ASSEMBLY / INSTALLATION SAFETY / SPECIFICATIONS GETTING STARTED OPERATION - DESCRIPTION OF MACHINE PARTS AND FUNCTIONS - CONTINUED The vertical rollers 8 4A The vertical rollers (4A) assist the machine by giving support to long material while allowing the material to glide smoothly during material feeding. The chip auger Keep hands, hair, and clothing away from the chip auger. Serious bodily injury can occur if clothing, hands, hair or other body parts become entangled in the auger. The chip auger automatically starts during the cutting cycle. The chip auger conveys chips out of the machine. The auger is driven by a hydraulic motor. Position a container or cart at the end of the machine to capture the chips. Limit switches 5A The forward limit switch limit switch (5A) stops the shuttle vise. Two similar switches (6A, 7A) are positioned on the hydraulic cylinder of the saw bow to limit the saw bow stroke. 6A (6A) Bow down limit switch 7A (7A) Bow up limit switch OPERATION - INTERFACE CONTROL SCREEN Keep your hands away from all cutting edges and moving parts. Never reach under the saw or workpiece. The blade is exposed in these areas and the guards cannot protect your body there. In case of an emergency situation Push the emergency shut off button down to stop all functions. To release the emergency shut off button rotate the mushroom shaped button clockwise. The button will pop up and the cutting cycle can be restarted. The Interface Control Screen may display error messages if there is a machine malfunction. A list of error codes and information can be found on page 19. The Interface Control Screen is a touch screen input window. It allows for the programming of operation variables. It will also display current operation parameters or errors. Operations are conducted in menu form. The Interface Control Screen is activated when the hydraulic pump is started. Press the hydraulic start button (B pg. 6) to begin. The interface will display a start page that shows the machine brand and model number along with the company logo.

9 Interface Control Screen - Main (Home) Menu - F Touch F1 button to display the screen shown above. 1. Feeding vise move position The numeric column shows shuttle vise moving position. 7 Zero (Home) Setting: This allows you to set the feeding vise zero position before executing automatic cutting when machine power has been shut Off then turned On again. Executing the zero setting should done be after clamping the front vise and opening the rear vise in the manual mode. 2. Operate mode Shows machine operation mode: Manual or Auto. 3. Working indicator lights The indicator lights show the current working status including Hydraulic, Blade Tension, Coolant, Work Light, Safe Height, Lower Limit Switch, Zero Point, Bench Vise Pressure, Shuttle Vise Pressure and Probe Arm Limit Switch. 4. Feeding (Shuttle) Vise Speed Touching this button toggles the Feeding Vise between Fast and Slow feed rates. 5. Blade running time Shows blade running time. Touch YES to start counting or zero setting after blade has been changed Touch the blade run time column to set the blade run time to zero, YES or NO. 6 A password is required to enter into this section. After the password is entered the Parameter Settings will appear. This page has already been set with default parameters before shipping. To enter this page you must key in the password and hit ENT. It is not necessary to make any changes in the parameter settings. Parameter changes should be only be made by a qualified personnel or distributor. Caution should be taking when making any changes in system parameters, because they can cause a malfunction in machine operation. 7. The Alarm Display Shows error notices when machine malfunctions occur and how to solve them. 8. Shows actual running blade speed. This page also records the history alarm data. Check the error data by moving right side vertical and horizontal arrow signs. (See pg. 19 for Troubleshooting help) 9. Set the blade speed. Touch to set blade speed directly and quickly. 10. Machine Execution Message. Interface Control Screen - Current Operations - F Touch the F2 button to display the screen shown above Execution Number Refers to the instruction task order. Touch it to go to page F3 Material Cutting Jobs. Touch next to display the next job. 12. Operation mode Shows machine execution mode: Manual or Automatic. 13. Quantity Setting Shows the quantity setting of the current instruction task that are to be completed. 14. Finished Quantity Shows the finished quantity of the current instruction task that have been completed. 15. Date and Time 16. Single Cutting or Bundle Cutting Touch this button to choose Single or Bundle Cutting. For Single Cutting operation, the Feeding (Shuttle) Vise will clamp at a position in the back to prepare for the next feed. When bundle cutting is selected the Feeding (Shuttle) Vise will stay at the front position after feeding material forward. 17. Machine Execution Message (Continues on next page) 9 GETTING STARTED SAFETY / SPECIFICATIONS ASSEMBLY / INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE / REPAIR

10 MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION ASSEMBLY / INSTALLATION SAFETY / SPECIFICATIONS GETTING STARTED Interface Control Screen - Current Operations - F2 (Continued) Count Trim Cut In or Out Touch this button to count trim cut in or out after starting automatic cutting cycle. 19. Feeding material length. Refers to the current total length of material that has fed forward. This includes distances beyond a single shuttle stroke. 20. Preset Length: - refers to the length setting of the current instruction task. This chart below shows machine execution issues (17) and remedies for them. Execution messages Hydraulic pump OFF Bench vise not clamping securely Front and rear vises are clamping. Zero setting incomplete Bow not released Choose execution No. Probe arm limit switch is off. Remedy Start hydraulic pump Close bench vise until indicator light is on. Open front vise or rear vise. Execute zero setting. Press bow rise button until indicator light is on. Touch the executive No. to choose the cutting job. Rise bow up. Interface Control Screen - Cutting Jobs Settings - F The F3 button for will display the screen shown above. 21. Execution No. Refers to the order of the cutting jobs No. from 1 to 10. The machine will display the selected jobs currently being performed in sequence from the top to the bottom. Touch the execution number (NO.) to choose the cutting jobs, the column will change its color to green. The execution chart will not appear if the cutting quantity has been finished or one of the columns (length or quantity) is zero. The F3 menu allows the user to set the variables for workpiece cutting. There are 10 job slots available for altering the production lengths and quantities. Touch Job No. 1, to set the length and quantity. Touch the Next button to go to the next page and so on for the next available jobs. To modify the cutting length (in manual mode) just touch the length and the next screen (shown below) will be displayed. Touch the cutting length (in manual mode) to set a new cutting length. The numeric keypad will display (shown above) after touching the cutting length. This action allows users the capability to set the variables for workpiece cutting. Key in the cutting length and touch the Enter button to finish the setting procedure.

11 22. Shows Manual or Auto Mode 23. Touch to clear all set data (back) to zero setting. Choose Yes or No from the following dialogue box 24. Touch to show the next job screen. This button shows Home at the end of the cutting jobs. Touching it will take you back to the Main (Home) F1 screen. To cancel a job touch the execution number. 25. Clear Settings for each operation. Press any CLR button for two seconds to clear length and quantity parameters. The settings will revert to zeroes. 26. Finished Quantity - refers to the number of cut pieces completed. 37. Quantity Setting - Set the cutting quantity procedure as same as the cutting length setting. There are 10 total job slots available for altering the production quantities. 28. Length Setting - refers to the length of cut pieces. Interface Control Screen - Language Settings - F4 The F4 button for will display the screen shown above. Choose one of the languages and press the Back to front page to return to the Main (Home) Screen. OPERATION - MACHINE ERROR NOTIFICATIONS The Interface Control Screen will show error notices when machine malfunctions occur. The screen will display the probable cause and possible remedies. A listing of errors and remedies can be on page 19 in the Troubleshooting section. OPERATION - SAW BLADE INSTALLATION AND GUIDE ADJUSTMENT Always disconnect the machine from its power source before changing blades or carrying out any maintenance procedure even in the case of irregular machine operation. Choose a proper saw blade best suited for the workpiece to be cut. The size and shape of the workpiece plus the type of material should all be considered when selecting an appropriate saw blade. Removing and installing the blade 1. Raise the saw bow to a height clearing the bench vise jaw, use switch F (pg. 6). 2. Disconnect the machine from the power source. 3. Open wheel cover (1B) and clean the chips out of the machine. 2B 4. Loosen the adjusting screws (2B) to loosen the carbide guides from the guide blocks. 5. Slide the left blade guide post to the right as far as possible. 3B 6. Release the blade tension by turning the blade tension lever to the Loosen position (3B) 4B 7. Unlock the chip brush handle (4B) then push the chip brush assembly down. 11 GETTING STARTED SAFETY / SPECIFICATIONS ASSEMBLY / INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE / REPAIR

12 MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION ASSEMBLY / INSTALLATION SAFETY / SPECIFICATIONS GETTING STARTED 12 5B 8. Remove the blade from both wheels (5B) and out of each blade guide. 9. Place the new blade onto the wheels and work the blade all the way up between the blade guide bearings. Make sure the blade back is against the vertical roller bearing. 10. The blade clip will automatically release from the blade when the blade starts moving. 11. Slowly to turn the blade tension lever (3B) to the half way to the Tighten position, check and adjust the blade hold on the blade wheels, then turn the lever to the tighten position to perform blade tension. The saw blade will be tensioned to the proper default tension. 12. Slide the left blade guide arm back to the left position. 13. Tighten the adjusting knobs (2B) so the tungsten carbide guides will properly fit to the blade. 14. Close the wheel cover (1B). 15. Connect the machine to the power, and turn the Manual/ Auto switch (D pg. 6) to manual mode. 16. Use the saw bow control knobs (X and Y pg. 6) to adjust the down-feed speed to zero Press the Bench Vise Close button (H pg. 6) until its indicator light illuminates. 18. Press the Operation Start Button (E pg. 6) to start the blade moving. After approximately two revolutions, press the Bow Up Button (F pg. 6) to stop the blade. 19 Open the wheel cover to see that the blade has not come off the wheels and is securely pressed against roller bearings. 20. Adjust the position of the wire brush to the gullets of the saw blade, then tighten it with the lock lever (4B). NOTE: In case the blade needs to be replaced, make sure to always install a blade of same thickness as the original blade. Breaking in the new saw blade When a new blade is installed, be sure to break in the blade before using it for production. Failure to break in the blade will shorten the service life of the blade, and result in less than optimum performance. To break in the blade, proceed as follows: Reduce the blade speed setting to one half of its normal setting. Lengthen the time required for cutting to 2-3 times longer than normal. The break-in operation can be considered sufficient if all unusual noises or metallic sounds have been eliminated. For instance, to completely break in the blade, a minimum of five complete cuts at 8 in diameter are required. After the break-in operation has been completed, return the blade speed and feed rate to their normal setting. Blade tracking adjustment 6B 7B 8B The blade tracking (shown above) is set by the factory and should not require any adjustment. The tracking adjustment must be made by a qualified personnel that are familiar with this type of procedure. Adjust the saw blade so that the back of the blade lightly touches the flange of blade wheels. Use the blade clip to hold the saw blade in place. If a tracking problem occurs, adjust the machine as follows: Raise saw arm to a usable height. Completely disconnect the machine from its power source. Locate tracking adjustment bolt on the backside of the saw bow behind the flywheel. Loosen nut (8B) and bolt (6B). Tracking adjustment is accomplished by either loosening or tightening the adjusting tracking nut (7B). Tracking is set properly when the back of the blade lightly touches the wheel flange.

13 NOTE: Over tracking (allowing blade back to rub hard against wheel flange) will damage the blade wheels and blade. Tighten locking bolt (6B) then tighten the nut (8B), after proper tracking is completed. Connect machine to the power source. Adjusting the tungsten carbide guides Before making any cuts in your the workpiece, the tungsten carbide guides must be adjusted by setting the adjusting screws so the bladed is properly guided without any binding. The tungsten carbide guides should touch, but not pinch the blade. To move the blade guide posts or change the blade, the tungsten carbide guides should be released by loosening the adjusting screw. OPERATION - PREPARATIONS The automatic vise clamps on this machine exert great pressure on the clamped workpieces when they are activated. Use extreme caution when placing, positioning and clamping stock with the vise clamps. Vise operation The vises can be opened to one full stroke when saw bow is raised to the highest limit. If the saw bow at a position below the highest limit, then the vises will only open approximately 3/16. They will not continue open when vise open buttons (J and K pg. 6) are pressed. The shuttle vise will not move material when the bench vise is clamped. The shuttle vise will not move material if the approach sensor is active. - If the vises are to be closed, then start with the bench vise. - If the vises are to be open, then start the shuttle vise. Securing the workpiece Raise the saw frame. Open the vise wide enough to insert the material. Place workpiece onto the roller table. Gently push the workpiece through the vertical rollers and into the shuttle vise, taking care not to hit the vertical rollers. The machine will automatically clamp the material in auto mode and the vise can close a full stroke to do so. In manual mode, use the vise close buttons (H and J pg. 6). Adjusting the guide posts The guide posts adjust horizontally to control the spacing of the blade guides. Having the blade exposed to the minimal amount helps provide better safety protection and more accurate cutting by reducing blade flexing. 9B Refer to the scale to adjust the distance. For most spacing changes, unlock the left guide (9B) post by turning locking wing bolt. Grip the posts and move horizontally. Lock into position by retightening the locking wing nut. Cutting pressure adjustment Alloy tool steels Chrome steels Heat resisting stainless steel Wide steel plate CUTTING PRESSURE VS. MATERIALS High carbon tool steel Bearing bronze steel Chrome steels Medium carbon steels Medium carbon steels General metal materials Thick metal pipes Steels Iron pipes Angle iron General steel Select suitable cutting pressure for the workpiece to be cut. This varies according to the size and shape of the workpiece, type of material, and what type of saw blade is being used. As a guide for materials: cutting hard, wide, tubing, or structural materials must to be done at a slower rate then mild steel bar. For the saw blade selection: high-speed steel is better than carbon steel and bi-metal alloy is better than high-speed steel. 13 GETTING STARTED SAFETY / SPECIFICATIONS ASSEMBLY / INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE / REPAIR

14 MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION ASSEMBLY / INSTALLATION SAFETY / SPECIFICATIONS GETTING STARTED Roughly, the ratio of feed speeds should be 1:2:3. The materials are listed on the control panel. Please refer to it for proper cutting pressure setting. Attaching the nesting clamps (optional) 14 11B 10B Attach the vertical hex pegs to the stationary vise and shuttle vise. Place the nestling clamp on to the hex pegs so that the short side of the clamp faces the motor side. The clamp with the hose pointing to the motor side (10B) should be placed on the stationary vise. The clamp with the hose pointing away from the motor (11B) should be placed on the shuttle vise. Attach the nestling clamps with cap nuts. The hex pegs should slide freely. For Shuttle Vise For Stationary Vise Connect the hydraulic hose fixtures to their fixture heads. The cap nuts may touch the bed slightly, don t tighten them too much, otherwise the vise can not move freely forward or backward. 12B 13B Loosen both side screws (12B) and slide side plate to adjust the width of vertical press (13B) to suit bundle material width, after setting tighten the side screws. After setting the width, tighten the side screws. Attach plates for cutting material width 14B Open the front vise, choose the attach plates (14B). Put plates on the front vise base for the workpiece width. There are four attach plates. The widths of plates are: two 1-3/16 plates, one 1-5/8 plate, and one 4-3/8 plate. OPERATION CYCLES Before starting to cut the workpiece, you must ensure that: The workpiece is well clamped. The saw blade is suitable for the material being cut. The lock lever of the blade guide post is tightened. Sufficient tension is placed on the saw blade. The wire brush is properly positioned. There is sufficient cutting fluid, and it is in good condition. The cutting length and quantity are set already. Preset the cutting pressure and cutting flow rate. Manual operation C A O P M F D K R B E G I L J H 15B Connect the main power by turning the switch (15B) to the on position. Press the Hydraulic Start button (B). Set the Auto/Manual Switch (D) to manual mode. X Y

15 Place the workpiece onto the vise. (Refer to Securing the Workpiece, pg. 13). Close the shuttle vises use the shuttle vise close button (J). Move the workpiece to the desired position. Use the shuttle vise Forward and Backward Buttons (L and M) Clamp the workpiece with the bench vise. Use the Bench Vise Button (H). Adjust the spacing of the blade guide post; refer to Adjusting the Guide Posts (pg. 13). Set the Blade Speed in manual mode. Use the blade speed items 9 on the Interface Control Screen for blade speed in the auto mode (pg. 9) Set the rate for the Cutting Pressure (X) and Bow Down-feed speed (Y); refer to Cutting Pressure chart. (pg. 13). Press Operation Start Button (E) to start the cutting operation cycle. Press coolant switch (P) to start the coolant pump and the indicator light will illuminate. The chip auger will also start turning. The saw bow will begin to descend quickly until the probe arm touches the work-piece. Then the blade descent speed will slow to the Cutting Pressure (X) and Down Feed (Y) settings. After completion of the cut, the saw blade will stop at the lower limit position. The bow stop location can be set at the upper position or lower position in manual cutting mode (see Current Operations pg. 9). Press the Bow up button (F) to raise the saw bow. The initial cut When inserting a new workpiece in automatic mode, the first cut piece will not be the proper size unless an end cut is performed. This initial cut will zero material length so that further cuttings will be performed accurately. Begin by inserting the material. Have the material slightly past the blade cut off line. Perform all the Automatic Operation setting procedures (shown on this page). Switch the operation to manual mode by using the Auto/ Manual Switch on the Interface Control Screen (D pg. 6). Start the initial trim cut with automatic mode. The initial trim cut can count trim cut in or count trim out by pressing the Count Trim cut in or out button (18 pg. 10) after start auto cutting. Automatic operation C A O P M F D R B E G I L J H 15B Connect the main power, by turning the power switch (15B) to the on position Press the Hydraulic Start Button (B). Set the Auto/Manual Switch (D) to manual mode. Clamp the workpiece; refer to Securing the Workpiece (pg. 13). Set the Auto/Manual Switch (D) to automatic mode. Set the cut-piece variables in the Interface Control Cutting Jobs Settings (pg. 10), and choose execution (29 on pg. 10). Adjust the spacing of the blade guide post (pg. 14). Set the Blade Speed (9 on pg. 9). Set the Blade Speed in manual mode (F1 pg. 6). Use F2 interface screen. Set the blade speed in auto mode. Set the rate for the Cutting Pressure (X) and Bow Down-feed speed (Y); refer to Cutting Pressure (pg. 13). NOTE: If starting with a new workpiece; refer to Initial Trim Cut (pg. 15) procedures. Press Operation Start Button (E) to start the operation cycle. Press (P) to start the coolant pump. The chip auger will also start turning. The saw bow will begin to descend quickly until the probe arm touches the workpiece. Then the blade descent speed will slow to the Cutting Pressure (X) and Down Feed (Y) settings. After completion of the cut, the saw blade will stop at the lower limit position. The saw bow will rise and workpiece will feed for the next cut. The cycle will continue until all commands have been completed. The machine will stop and the motor will turn off. K X Y 15 GETTING STARTED SAFETY / SPECIFICATIONS ASSEMBLY / INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE / REPAIR

16 MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION ASSEMBLY / INSTALLATION SAFETY / SPECIFICATIONS GETTING STARTED OPERATION - MISCELLANEOUS Bundle cutting Begin by attaching the nestling clamps to the vises; refer to Attach the Nestling Clamps (pg. 14). Follow either the Manual Operation (pg. 15) procedures or the Automatic Operation (pg. 16) procedures. Set the system to bundle cutting; refer to Other Setting (21 pg. 10). Clamping operations are the same. The switches, (J and K); that operate the vises also operates the vertical motion of the nestling clamp. So, if you open the shuttle vise then the nestling clamp on the shuttle vise will open. And if you close the shuttle vise the nestling clamp on the shuttle vise will close. Freeing a bound blade Always disconnect the machine from its power source before changing blades or carrying out any maintenance procedure even in the case of irregular machine operation. If the saw blade suddenly becomes bound in the workpiece during a cut, press the frame raise button (F) to lift the saw frame immediately and disconnect the machine from it s power source. The saw blade jamming in the workpiece is most likely caused by one of the following issues: 16 Slippage occurring between saw blade and drive wheel. Tension placed on the saw blade is not sufficient. Slippage occurring between drive belt and motor pulley. Tension on drive belt is not sufficient or belt is worn. Broken teeth on the saw blade. Too blunt a saw blade. Too fine tooth spacing on saw blade for material being cut. Too fast feed rate for material being cut and blade used. Stopping the machine In event of an emergency, press either the Emergency Stop Button (C), or the Bow Up Switch (F), to stop all machine functions. It is recommended using the Bow Up Switch (F), because the emergency stop button will cancel all the machine settings. When using the Bow up Switch, the workpiece will still be clamped. Also, the machine can be stop between task cycles switching to Manual Mode with Auto/Manual Switch (D). Using this switch will cause the machine to stop at the end of current task. NOTE: If the hydraulic pump is on and the machine has not been active for 5 minutes, the power will be shut off automatically. The machine will need to be restarted to reactivate the hydraulic pump. Coolant heater operation 22B This band saw equipped with coolant heater that ensures the cutting coolant flows properly in colder weather. The heater power switch located in the control cabinet as shown above. There is a power breaker switch (22B) for coolant heater using in the cool weather. Switch on the power switch when in using. Switch off the power switch when not in using. 23B A knob is for setting coolant temperature (23B) is located at rear of base, under blade motor as shown above.

17 NOTES 17 GETTING STARTED SAFETY / SPECIFICATIONS ASSEMBLY / INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE / REPAIR

18 MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION ASSEMBLY / INSTALLATION SAFETY / SPECIFICATIONS GETTING STARTED OPERATION - MACHINE AND STEEL REFERENCE INFORMATION Machine capacities and specifications / /16 x 11-13/16 6 to 9-3/4 x 4 to 5 Steel types and characteristics Electric motor...3 HP Blade size...1 x.035 x 138 Blade speed to 262 FPM Working table height /2 Machine weight... 3,725 lbs.

19 TROUBLESHOOTING GUIDE The Interface Control Screen will show error notices when machine malfunctions occur. They will display the probable causes and possible remedies. Follow the remedies to resolve the problem and press reset button to remove the Error Notice. The diagram on the left shows a map with numbers identifying the location of various malfunctions. Location of Malfunction Possible Cause(s) Corrective Action Abnormal forward limit switch 1. Check forward limit switch 2. No material in the shuttle vise 1. Check material in the shuttle vise 3. Abnormal rotary encoder 1. Check rotary encoder wires 4. Abnormal shuttle-vise pressure sensor 5. Abnormal bench-vise pressure sensor 2. Check rotary encoder function 1. Check shuttle vise pressure sensor function 1. Check bench vise pressure sensor function 6. Abnormal blade tension 1. Check for broken blade 2. Check for blade tension 3. Check blade sensor 7. Abnormal probe arm limit switch 1. Check probe arm limit switch 2. Check probe arm sliding function 8. Abnormal bow down limit switch 1. Check bow down limit switch 9. Blade cover opened 1. Check blade cover limit switch 2. Close blade cover 10. Abnormal motor inverter 1. Check motor inverter 11. Abnormal blade motor blade motor 1. Check overload relay of blade motor 12. Abnormal hydraulic motor 1. Check overload relay of hydraulic motor 13. Abnormal coolant motor 1. Check overload relay of coolant motor 14. Emergency button locked 1. Rotate and release Emergency button 19 GETTING STARTED SAFETY / SPECIFICATIONS ASSEMBLY / INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE / REPAIR

20 MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION ASSEMBLY / INSTALLATION SAFETY / SPECIFICATIONS GETTING STARTED TROUBLESHOOTING GUIDE Symptom Possible Cause(s) Corrective Action Tooth breakage Cut advancing too quickly Decrease cutting advance, exerting less cutting pressure. Adjust the braking device. 20 Wrong cutting speed Wrong tooth pitch Chips sticking to the teeth and in the gullets or material that gums Defects on the material or material too hard Ineffective gripping of the part in the vise. The blade gets stuck in the material Starting cut on sharp or irregular section bar Poor quality blade Previously broken tooth left in the cut Resuming a cut on a previously made groove Vibrations Wrong tooth pitch or shape Insufficient coolant. Coolant not flowing or wrong coolant Teeth positioned in the direction opposite the cutting direction Change speed and/or type of blade to better match the material being cut. Replace blade choosing the proper tooth pitch to better match the material being cut. Check to ensure the coolant is being dispersed properly. Material surfaces can be oxidized or covered with impurities making these areas harder than the blade itself. Materials may have hardened areas or inclusions inside the section due to production materials such as castings and welding wastes, etc. Avoid cutting these materials. In a situation where a cut has to be made use extreme care, cleaning and removing hard impurities as quickly as possible. Check the gripping of the part being cut. Make sure the parts are securely held. Decrease the cutting advance and exert less cutting pressure. Decrease the cutting advance to allow the blade to begin its initial cut. Switch to a superior quality blade. Remove in the broken tooth from the cut. Make the cut elsewhere, turning the part over. Check the grip of the part being cut to ensure it is being held securely in the vise. Replace blade choosing the proper tooth pitch or shape to better match the material being cut. Check level of coolant in the tank. Check to ensure the coolant is flowing freely. Check the lubricant viscosity. In cold situations the coolant may need to be heated with the optional heater. Check and user proper lubricant. Remove the blade and reinstall it with the teeth cutting in the proper direction.

21 TROUBLESHOOTING GUIDE Symptom Possible Cause(s) Corrective Action Premature blade wear Faulty blade break-in Break in a new blade. (See pgs. 12 and 13) Teeth positioned in the direction opposite of the cutting direction Poor quality blade Cut advancing too quickly Wrong cutting speed Defects on the material or material too hard Insufficient coolant. Coolant not flowing or wrong coolant Remove the blade and reinstall it with the teeth cutting in the proper direction. Switch to a superior quality blade. Decrease cutting advance, exerting less cutting pressure. Change speed and/or type of blade to better match the material being cut. Material surfaces can be oxidized or covered with impurities making these areas harder than the blade itself. Materials may have hardened areas or inclusions inside the section due to production materials such as castings and welding wastes, etc. Avoid cutting these materials. In a situation where a cut has to be made use extreme care, cleaning and removing hard impurities as quickly as possible. Check level of coolant in the tank. Check to ensure the coolant is flowing freely. Check the lubricant viscosity. In cold situations the coolant may need to be heated with the optional heater. Check and user proper lubricant. Blade breakage/damage Faulty welding of blade Switch to a superior quality blade. Cut advancing too quickly Wrong cutting speed Wrong tooth pitch Ineffective gripping of the part in the vice Blade touching material at beginning of cut Decrease cutting advance, exerting less cutting pressure. Adjust the braking device. Change speed and/or type of blade to better match the material being cut. Replace blade choosing the proper tooth pitch. to better match the material being cut. Check the gripping of the part being cut. Adjust the position of the material being cut so the vise clamps better. The saw bow should advance quickly and then slow before beginning a cut. Have a qualified technician troubleshoot any issues. 21 GETTING STARTED SAFETY / SPECIFICATIONS ASSEMBLY / INSTALLATION OPERATION TROUBLESHOOTING MAINTENANCE / REPAIR

22 MAINTENANCE / REPAIR TROUBLESHOOTING OPERATION ASSEMBLY / INSTALLATION SAFETY / SPECIFICATIONS GETTING STARTED TROUBLESHOOTING GUIDE Symptom Possible Cause(s) Corrective Action Blade breakage/damage 22 Blade guide not adjusted properly or dirty because of lack of maintenance. Blade guide block too far from material to be cut Improper position of blade on flywheels Insufficient lubricating coolant or wrong emulsion Check, clean and adjust the blade tracking to ensure the blade travels freely and true. (See pg. 13) Set the approach head closely to the material being cut so that only the blade section used in the cut is free, this will prevent deflections that stress the blade. Check the alignment of the blade on the flywheels and adjust as needed. (See pgs. 12 and 13) Check level of coolant in the tank. Check to ensure the coolant is flowing freely. Check the lubricant viscosity. In cold situations the coolant may need to be heated with the optional heater. Check and user proper lubricant. Streaked or etched bands Damaged or chipped blade guide pads Replace the blade guide pads. Tight or loose tungsten carbide guide Correctly adjust the tungsten carbide guides. (See pg. 14) Streaked cutting surface Cut advancing too fast Decrease the speed of the cut advance, exerting less cutting pressure. Adjust the braking device. Poor quality blade Worn out blade or with chipped and/or broken teeth Wrong tooth pitch Tungsten carbide blade guide block too far from material to be cut Insufficient coolant or wrong emulsion Replace blade with a superior quality blade to better match the material being cut. Replace it with a new blade. The teeth in the blade being used are probably large. Use a blade with higher TPI. Replace blade choosing the proper tooth pitch. Set the approach head closely to the material being cut so that only the blade section used in the cut is free, this will prevent deflections that stress the blade. Check level of lubricating coolant level in the tank. Increase the flow of lubricating coolant, checking to ensure the hole and the liquid outlet pipe are not blocked. Check the emulsion percentage.