User Manual - Industrial Tool and Machinery Sales
Contents
1. 3 5 The Base Lane Chapter 4 OPERATING AND ADVICE ON USING YOUR BANDSAW 4 1 The Operation Cycle sss 4 2 Recommendations for Using the Machine Chapter 5 ADJUSTING YOUR MACHINE 5 1 Blade Tension Assembly 5 2 Aligning the Flywheel 5 3 Checking the Adjustment of the Blade 5 4 Adjusting the Blade Guide 5 5 Changing the Blade Chapter 6 ROUTINE AND SPECIAL MAINTENANCE 6 1 Daily Maintenance 9 6 2 Weekly Maintenance 8 6 3 Monthly Maintenance 8 6 4 Six monthly Maintenance 8 6 5 Oils for Lubricating Coolant 8 65 Oll BENEA Aae 8 67 Goolatit SSE 8 0 THE GediDOX EN 8 6 9 Special Maintenance eee ee ee 8 Chapter 7 TECHNICAL CHARACTERISTICS 7 1 Table of Cutting Capacity and Technical Details RE 9 Chapter 8 MATERIAL CLASSIFICATION AND CHOICE OF TOOL 8 1 Definition of Materials 9 8 2 Selecting Blade sees 9 9 STEN PICI e 10 8 4 Cutting and Advance Speed esse 10 8 5 Blade Running in 10 3 6 Blade otruclile s nda evi uti ri 10 9 7 Blade NE 10 Chapter 9 NOISE ES 11 Chapter 10 WIRING2. 1 186 jFrontBallBearngSeat J1 mma Shaft Tt t8 PipeFiting 142 Ball Bearing 82006 2 188 RearBladeGuard J1 143 idle Flywheel 1 188 BladeGuide 28 i45 Star Washer M30 1 1191 RearBallBearng Seat J1 148 Blade 1 933 Int Me 2 149 Blade Cover 1 1194 HexCapBot IMex12 2 151 RoundHeadScrew M4x8 2 196 BrushSetRing 1 155 Hex CapBot M1Ox25 1 198 Bracket 1 156 Spring Washer IM1O 1 1998 Brush 157 Washer 1 200 Eccentric Shaft 20 158 DrveFlywheel 1 201 Ball Bearing 608ZZ 8 gt 159 Hex SocketCapScrew M10x40 4 202 BladeGuide 1 2 160 Spring Washer IM1O 4 203 Hex SocketCapScrew M6x25 2 162 Pipe Fitting 14Px5716 1 205 Centric Shat _ 6 2 163 PipeFitingSeat 1 206 Ball Bearing 608ZZ 2 8 981005 Ee LA GOOL86 HS SOZZ dM 20 LA G00L86 801 lt E LOI 7 s NG i Rs 01 Lo NE 201 Si 0 1 07 98 ou 4 oy 1 86 POLK lg pe U A WO PN V 9 6 OG GG HS SOLC dM 21 95900186 IEI 0D66I DEI 0 81 DII Ser Om ML V 0GT Z V HZLI HS0Zc dM HS SOLC dM 209 LA S00186 C V6I OG 2 061 161 L 291 691 5 5026 23 900186 1eyoeJg Bune
3. Squeeze the trigger on the control handle E to start the blade and lower saw bow to begin cutting When the saw bow reaches the bottom the micro switch will activate and the blade will stop Keep hold of the control handle to control the return to the start position Close the hydraulic regulation lever V he cutting operation is complete Reset the work piece to continue the next cutting cycle 3 Semi auto Cutting Operation of 270SH WARNING Failure to fully close the hydraulic flow control knob J and locking the hydraulic regulation lever V can result in serious injury The saw bow may drop suddenly when changing the spring tension Close the hydraulic regulation lever V by switching it clockwise Increase the bow weight Rotate the wing nut K counter clockwise to reduce the spring tension Load work piece and clamp it properly Turn main connect switch A to the ON position Check to see that the indicator light B is lit Select Hydraulic mode on control switch F turn the switch to the right Press the start button C The coolant system should activate at the same time Open the hydraulic regulation lever V by switching it counter clockwise Slightly turn the hydraulic flow control knob J counter clockwise from 2 3 to control the saw bow s descent rate When the saw bow reaches the bottom the micro switch will activate and the blade will stop Lift the saw
4. ALTERNATE SET INDIVIDUAL TEETH Cutting teeth right and left mi T at HR et H r hd This set is used for the cutting of nonferrous soft materials plastics and wood The test was held under environmental noise levels of 65db Noise measurements with the machine operating unload was 71db Noise level during the cutting of mild carbon steel was 73db NOTE with the machine operating the noise level will vary according to the different materials being processed The user must therefore assess the intensity and if necessary provide the operators with the necessary personal protection as required by Law 277 1991 244 2 10 WIRING DIAGRAMS Model WP 270S 1 L e 8 8 6 x J 3 4 F 0 0 75mm 2 1 Tc L1 R L2 S PE COOLER 1 Option 5 SB1 QS1 Main switch SAW KM1 Contact FR1 Overload relay FR2 Thermal Protector Motor TC Transformer FU Transformer output HL AC Lamp SB1 Emergency button SB2 Start SQ1 Limit switch SQ2 Limit switch 980915 V1 1 L 9 GJERE 8 77 35 4P 8P gr 0 75mm 1 25mm Te L1 R 24VAC 0 2 meer L3 T i PE COOLER SB1 QS1 Main switch KM1 Contact FR1 Overload relay FR2 Thermal Protector Motor TC Transformer FU Transformer output HL AC Lamp SB1 Emergency button SB2 Start SQ1 Limit switch SAW Motor SQ2 Limit switch SQ1 SB1 980915 V1 S Model WP 270
5. Before carrying out any repairs on the machine consult the dealer 5 ADJUSTING YOUR MACHINE 5 1 Blade Tension Assembly Blade tension is important to the proper operation of the Saw Proper blade tension is 700 to 900 kg mm as measured on a blade tension gauge To set the blade tension without the use of a tension gauge Disconnect the machine from the power source Install blade between wheel and insert blade between bearings on blade guides Tension blade slightly to remove any sag in blade between blade wheels Turn blade tension handle L one and three quarter to two revolutions clockwise To test press the flat side of the blade with your thumb if moves with 2mm 3mm range then it is set correctly After blade has been completely installed close covers connect the power source and run saw for two to three minutes so blade can seat properly Disconnect machine from the power source Open cover and loosen blade just until it begins to sag Tighten blade until it becomes straight between blade wheel and all sag has been eliminated Tighten blade by turning blade tension wheel two full revolutions Blade is now property tensioned and ready for use Close covers and connect machine to the power Source 5 2 Aligning the Flywheel The flywheel s alignment may need adjustment to allow the saw blade to track correctly Poor flywheel alignment can cause damage to the saw blade or to
6. CUTTING CAPACITY O Lt tt 90 227mm 220mm 260x110mm 45 150mm 145mm 200x125mm 60 90mm 85mm TYPES OF STEEL 4 Construction e360 Saale Fe430 E28 e310 CHARACTERISTICS USA Hardness araness AISI SAE Mii n ROCKWELL R N mm 360 480 430 560 510 660 Carbon 060 A 40 steels Z C60 10 1220 1400 0 880 1080 930 1130 760 1030 690 980 X A 62 Spring 50CrV4 50CrV4 50CV4 735A50 6150 207 5 steels 60SiCr8 60SiCr7 9262 224 98 Alloyed steels for 39NiCrMo4 36CrNiMo4 nitriding 41CrAIMo7 41CrAIMo7 35CrMo4 34CrMo4 35CD4 708 A 37 4135 220 39NCD4 9840 228 99 40CADG12 905 M 39 22 100 Alloyed 18NiCrMo7 20NCD7 En 325 4320 casehardening steels 20NiCrMo2 21NiCrMo2 20NCD2 805H20 4315 Alloyed for 100Cr6 100Cr6 100C6 534A99 52100 52NiCrMoKU 56NiCrMoV7C100K 5 C100KU C100W1 BS 1 X210Cr13KU X210Cr12 Z200C12 BD2 BD3 58SiMo8KU Y60SC7 X12Cr13 4001 X5CrNi1810 4301 Z5CN18 09 304 C 12 X8CrNi1910 X8CrNiMo1713 4401 enn 12 316S 16 690 980 800 1030 00 820 1060 800 1030 670 885 590 685 540 685 490 685 Tool steel Stainless steels Copper alloys Aluminium copper alloy Special brass Bronze anganese bronze SAE43 SAE430 Phosphor bronze G CuSn12 UNI 7013 2a Gray pig iron Cast iron Spneroka graphite cast iron GS600 Malleable cast iron W40 05 8 MATERIAL CLASSIFICATIONS AND CHOICE OF TOOL S
7. 1 gt 22 Hex SocketCapScrew M8x20 2 176 EmergencySwitch 10 23 FiterNet 1 fz Powerindicator Light 1 24 RoundHeadScrew M5x10 4 78H Manual Auto Selector 1 25 Hex Socket Cap Screw M6x25 2 79H StartButon 10 26 Washer M6 2 j amp 8H PVGPanl 1 i 27 HoseClamp 13mm 1 80 IPVCPanel 6 10 27 Hose 516xl30com 1 80 1 PlasticBox 1 1 238 Pump J 1 88 jFweSett 29 Hex CapBot M1Ox20 4 82 Transformer t1 291 Washer M1Ox26x2 4 83 OveroadRelay 10 30 Coolant and Chip Tray 1 84 Magnetic Connector 1 30 1 FrontCoolantTray 1 185 RoundHeadScew M5x10 8 30 2 Hex SocketCapScrew M6x8 2 8 Control Bracket 10 31 HexCapBot M2x40 2 89 Hex SocketCapScrew M8x2O 2 32 Nt M12 2 90 SpringWasher M8 2 38 HandWheel IRE 1 Setting Bracket 1 gt 401 SetScrew IlIM5x 1 SwivelArm t gt 41 Bearing Bushing 1 1941 Scale 1 10 48 LokHande 11198 Disk 1 44 Bushing 1 1 87 Se lmm 1 gt 45 Hex SocketCapScrew M6x100x28 2 98 Shaft o 10 46 Movable Vise J 1 j9 Nt 47 Plate 1 100 Hex Socket Cap Screw M8x3O 4 49 CompresedSping 1 102 Set Screw M8xX10 1 gt 50 LeadScewv 1 1103 Hex SocketCapScrew M10x35 1 981005 18 PART LIST oon wee ovn eewew ee ov o
8. WP 270Series For models WP 270S and WP 270SH HORIZONTAL METAL CUTTING BAND SAW Study Carefully Before Operating WP 270S WP 270SH Specifications Motor Capacity 3 a 1 1kW 1 5HP 90 227mm 220x220mm 260x110mm Packing size L xWxH 45 150mm 145x145mm 200x125mm 1549x737x1054mm 60 90mm 85x85mm Container Loads Blade Size 22 units 20 46 units 40 27x0 9x2460mm NW 216kgs GW 250kgs Blade Speed 50Hz 4P 72m min 8P 36m min 10 2009 Contents Chapter 1 ACCIDENT PREVENTION AND SAFETY REGULATION 1 1 Advice for the Operator 1 2 The Electrical Equipment According to European Standard CENELEC EN 60204 1 1 3 Emergencies According to European Standard CENELEC EN 60204 1 Chapter 2 MACHINE DIMENSIONS TRANSPORT INSTALLATION DISMANTLING 2 1 Machine Dimensions 2 2 Transportation of Your Machine 2 3 Minimum Requirements for Housing the Machine 2 4 Position the Machine 2 5 Instructions for Assembly of the Loose Parts and Accessories 2 6 Deactivation of Machine s 2 7 Dismantling Chapter 3 THE MACHINE S FUNCTIONAL PARTS 3 1 The Saw Bow 3 2 Controls cueste ertet 3 3 Vise Adjustment 3 4 Cutting Angle Adjustment
9. Increase the flow of lubricating refrigerant checking that the hole and the liquid outlet pipe are not blocked Check the emulsion percentage Turn teeth to correct direction FAULT PREMATURE BLADE WEAR BLADE BREAKAGE PROBABLE CAUSE Faulty running in of blade Teeth positioned in the direction opposite the cutting direction Poor quality blade Too fast advance Wrong cutting speed Defects on the material or material too hard Insufficient lubricating refrigerant or wrong emulsion Faulty welding of blade Too fast advance Wrong cutting speed Wrong tooth pitch Ineffective gripping of the part in the vice Blade touching material at beginning of cut Remedy REMEDY See Material classification and blade selection in the Blade running in section Turn teeth in correct direction Use a superior quality blade Decrease advance exerting less cutting pressure Adjust the braking device Change speed and or type of blade See chapter on Material classification and blade selection in the section Blade selection table according to cutting and feed speed Material surfaces can be oxidized or covered with impurities making them at the beginning of the cut harder that the blade itself or have hardened areas or inclusions inside the section due to productive agents used such as casting sand welding wastes etc Avoid cutting these materials or perform cutting with extreme care cle
10. DIAGRAM ee 12 Chapter 11 TROUBLESHOOTING 11 1 Blade and Cut Diagnosis 14 Chapter 12 MACHINE COMPONETS 18 12 2 Explosion Drawings 20 1 ACCIDENT PREVENTION AND SAFETY REGULATION This machine has been designed to comply with national and community accident prevention regulations Improper use and or tampering with the safety devices will relieve the manufacturer of all responsibility 1 1 Advice for the Operator Check that the voltage indicated on machine motor is the same as the line voltage Check the efficiency of your electric supply and grounding system connect the power cable of the machine to the socket and the ground lead yellow green in color to the grounding system When the saw frame is in suspended mode or raised the blade must not move Only the blade section used for cutting must be kept unprotected To adjust the blade guards use on the blade guides It is forbidden to use the machine without its shields Always disconnect the machine from the power Socket before blade change or carrying out any maintenance job even in the case of abnormal machine operation Always wear suitable eyes protection Never put your hands or arms into the cutting area while the machine is operating Do not shift the machine while it is cutting Do not wear loose clothing like shirts with sleeves that are too long gloves that a
11. If necessary cover the machine 2 7 Dismantling due to deterioration and or obsolescence General rules the machine is to be permanently demolished and or scrapped divide the material to be disposed of according to type and composition as follows 1 Non composite cast iron or ferrous materials are recyclable raw materials so they may be taken to an iron foundry for re smelting after having removed the contents classified in point 3 2 Electrical components including the cable and electronic material magnetic cards etc fall within the category of material classified as being assimilated to urban waste according to the laws of your local state or federal government so they may be set aside for collection by the public waste disposal service 3 Old mineral and synthetic and or mixed oils emulsified oils and greases are considered hazardous or special refuse so they must be collected transported and disposed of at a special waste disposal service NOTE The standards and legislation concerning refuse is in a constant state of evolution therefore is subject to changes The user must keep informed of the regulations at the time of disposal as these may differ from those described above 3 THE MACHINE S FUNCTIONAL PARTS 3 1 The Saw Bow The saw bow is a collection of machine parts consisting of a saw bow drive members gears transfer motor blade wheel blade tension system blade guides and bl
12. allow the blade to ride off the blade wheels Setscrew D a c TOP 9 Raise the saw bow to a usable work height Disconnect the power supply Loosen the Hex nut screws A B and C Use and Allen wrench on setscrew D to adjust the tilt of the flywheel Turning the setscrew D clockwise will tilt flywheel so that the blade will ride closer to the flange Turning the setscrew D counter clockwise will tilt the flywheel so that the blade will ride away from the flange If the blade rides too far then it will come off After the adjustment is finish fasten the Hex nut screws in this order A B and C TOP VIEW tilt blade rides towards the flange tilt blade rides away from the flange Flange set screw D 5 3 Checking the Adjustment of the Blade Use a strip of scrap paper and slide it between the blade and the flywheel while it is running f the paper is cut then the blade is riding too close to the flange Readjust f the paper folds or creases then the blade is seated properly f you notice that the blade is riding away from the flange then readjust flywheel blade direction 5 4 Adjusting the Blade Guide Disconnect the machine from the power source Release the extension bar for the blade guide block Use the hex socket screw N to loosen the clamping block O Hold the revolving handle M and slide the blade guide block t
13. by loosening the four SetSCreWS Remove the pump Q by loosening the four setscrews Use a vacuum cleaner to vacuum chips and debris from the tank Replace the plug T Thoroughly clean the pump Q and replace Fill the tank with coolant to approximately 25mm below the grate P Replace the grate P Allow 6 8 The Gearbox The gearbox requires periodic changing of oil The oil must be changed by the first six months of a new machine and every year thereafter To change the gear box oil Disconnect the machine from the power source Raise the saw bow to vertical position Release the drain hole S to draw off gear oil by loosening the oil fill bolt R Replace the drain plug bolt S after oil completely flows off Place the saw bow back to horizontal position Fill Gear box with approximately 3 liter of gear oil through the hole of the oil fill bolt R For reference use SHELL type gear oil or Mobile gear oil 90 6 9 Special Maintenance opecial maintenance must be conducted by skilled personnel We advise contacting your nearest dealer and or importer Also the reset of protective and safety equipment and devices of the reducer the motor the motor pump and other electrical components requires special maintenance 7 TECHNICAL CHARACTERISTICS 7 1 Table of Cutting Capacity and Technical Details BLADE MOTOR 1 1 BLADE SIZE 2 x0 9x2460 BLADE SPEED 36 72 WORKING TABLE HEIGHT 890 MACHINE WEIGHT 216
14. wrong emulsion Teeth positioned in the direction opposite the cutting direction REMEDY Decrease advance exerting less cutting pressure Adjust the braking device Change speed and or type of blade See chapter on Material classification and blade selection in the section Blade selection table according to cutting and feed speed Choose a suitable blade See Chapter Material classification and blade selection Check for clogging of coolant drain holes on the blade guide blocks and that flow is plentiful in order to facilitate the removal of chips from the blade Material surfaces can be oxidized or covered with impurities making them at the beginning of the cut harder that the blade itself or have hardened areas or inclusions inside the section due to productive agents used such as casting sand welding wastes etc Avoid cutting these materials or ina situation a cut has to be made use extreme care cleaning and remove any such impurities as quickly as possible Check the gripping of the part Reduce feed and exert less cutting pressure Pay more attention when you start cutting Use a superior quality blade Accurately remove all the parts left in Make the cut elsewhere turning the part Check gripping of the part Replace blade with a more suitable one See Material classification and blade selection in the Blade Types section Adjust blade guide pads Check level of liquid in the tank
15. 8 A1 2004 A2 2007 Limits and methods of measurement of radio interference characteristics of industrial electrical device The European Standard IEC 61000 6 2 2005 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments The European Standard IEC 61000 6 4 2001 A 11 2004 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standards for industrial environments The European Standard EN ISO 12100 1 2003 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology The European Standard EN ISO 12100 2 2003 Safety of machinery Basic concepts general principles for design Part 2 Technical Principles The European Standard EN ISO 14121 1 amp 2 2003 Safety of Machinery Risk Assessment The International Standard ISO 13852 2003 Safety of machinery Safety distances to prevent danger zones being reached by the upper limbs EN 13898 2003 Machine tools Safety Sawing machines for cold metal Date Signature 0 Cat Lilie Qualification General Manager
16. OOTH pitch varies between teeth and consequently varying teeth size and varying gullet depths Pitch varies between teeth which ensures a smoother quieter cut and longer blade life owing to the lack of vibration distance between teeth olim san LP ee RK 10 Another advantage offered in the use of this type of blade in the fact that with an only blade is possible to cut a wide range of different materials in size and type COMBO TOOTH 95 10 positive rake positive hx This type of blade is the most suitable for the cutting Of section Dars and large and thick pipes as well as for the cutting of solid Dars at maximum machine capacity Available pitches 3 4 4 6 SETS Saw teeth bent out of the plane of the saw body resulting in a wide cut in the workpiece REGULAR OR RAKER SET Cutting teeth right and left alternated by a straight tooth Of general use for materials with dimensions superior to 5 mm Used for the cutting of steel castings and hard nonferrous materials 9 NOISE TESTS WAVY SET Set in smooth waves This set is associated with very fine teeth and it is mainly used for the cutting of pipes and thin section bars from 1 to 3 mm ALTERNATE SET IN GROUPS Groups of cutting teeth right and left alternated by a straight tooth This set is associated with very fine teeth and it is used for extremely thin materials less than 1mm
17. SH D COOLER Main switch Start push button Selector switch Lamp Transformer Transformer output Over load relay Thermo switch Emergency stop Trigger switch Automatic shutoff limit switch Blade cover limit switch Blade broken limit switch optional Contact 980506 V1 LIMITE O a 1 D SA1 Hi Low speed switch SA2 Start push button SA3 Selector switch Lamp TC Transformer FU Transformer output FR1 Overload relay FR2 Thermo switch SAW Motor SB1 Emergency stop SB2 Trigger switch SQ1 Automatic shutoff limit switch SQ2 Blade cover limit switch SQ3 Blade broken limit switch optional KM1 Contact 980506 V 1 1 11 TROUBLESHOOTING This chapter lists the probable faults and malfunctions that could occur while the machine is being used and suggests possible remedies for solving them 11 1 Blade and cut diagnosis FAULT TOOTH BREAKAGE PROBABLE CAUSE Too fast advance Wrong cutting speed Wrong tooth pitch Chips sticking onto 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 bars Poor quality blade Previously broken tooth left in the cut Cutting resumed on a groove made previously Vibrations Wrong tooth pitch or shape Insufficient lubricating refrigerant or
18. ade guards The WP 270SH model also includes a hydraulic cylinder and adjustable counter balance spring 3 2 Controls For model WP 270S D For model WP 270SH Main Connect Switch Power Indicator Light Start Cutting Push Button Emergency Push Button ON OFF Trigger and Control Handle Manual or Hydraulic Operation Selector MOON 3 3 Vise Adjustment 4 OPERATING AND ADVICE ON USING YOUR BANDSAW 4 1 The Operation Cycle Before operating the machine all the main parts of the machine must be set to the optimum conditions Power and blade speed select switch Clamping the Work Piece Place the work piece between the vise jaws and have it rest next to the fixed vise jaw Rotate the hand wheel G clockwise to close the free vise jaw on to the work piece and tighten Rotate the hand wheel G counter clockwise to release Lever H can be used to rapidly lock and release the work piece by allowing a shallow gap between the vise and work piece Then rotate lever H counter clockwise to lock and clockwise to release Their are three positions can be selected Off Rabbit or Turtle on the main switch if select blade speed must be exactly turned towards Rabbit or Turtle sign in cutting situation 3 4 Cutting Angle Adjustment The WP 270S is equipped with manually trigger Cutting at angles handle switch Angle can be cut up to 60 Unlock lever I by pushing it to the left side 1 Manu
19. al Operation of 270S Rotate the saw bow to the desired angle by following the index on the scale Lock lever by pushing to the right side 3 5 The Base The base is a structure supporting the saw bow the vise the bar stop the work piece supporter pump swing arm and the coolant return plate for the support of the material The base houses the cooling liquid tank Load work piece and clamp it properly Turn on main connect switch A to the ON position Fast speed or Low speed Check to see that the indicator light B is lit Hold the control handle E of the saw bow Squeeze the trigger on the control handle E to start the blade and lower saw bow to begin cutting When the saw bow reaches the bottom release the trigger switch and the blade will stop Keep hold of the control handle to control the saw head return to the start position 2 Manual Operation of 270SH Reduce the bow weight Rotate the wing nut K clockwise to increase the tension on the spring Load work piece and clamp it properly Turn on main connect switch A to the ON position Check to see that the indicator light B is lit Select manual control mode Turn the control switch F to manual control mode for trigger operation Hold the control handle E of the saw bow Fully open the flow control knob J by rotating counter clockwise to the maximum and open the on off hydraulic switch V to on position
20. aning and remove such impurities as quickly as possible Check level of liquid in the tank Increase the flow of lubricating coolant checking that the coolant nozzle and pipe are not blocked Check the emulsion percentage The welding of the blade is of utmost importance The meeting surfaces must perfectly match and once they are welded they must have no inclusions or bubbles the welded part must be perfectly smooth and even They must be evenly thick and have no bulges that can cause dents or instant breakage when sliding between the blade guide pads Decrease advance exerting less cutting pressure Adjust the braking device Change speed and or type of blade See chapter on Material classification and blade selection in the section Blade selection table according to cutting and feed speed Choose a suitable blade See Chapter Material classification and blade selection Check the gripping of the part At the beginning of the cutting process never lower the saw bow before starting the blade motor FAULT STEAKED OR ETCHED BANDS CUTS OFF THE STRAIGHT PROBABLE CAUSE Blade guide pads not regulated 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 Damaged or chipped blade guide pads Tight or slackened blade guide bearings Blade not parallel as to the c
21. bow to the appropriate height close the hydraulic regulation lever V by rotating it clockwise all the way to the end he machine is now ready for the next cutting operation If may has an emergency situation should occur Press the emergency push button D down to shut off all functions To release the emergency pushbutton rotate the mushroom shaped button in the clock wise direction he button will pop up then the cutting cycle can be restarted 4 2 Recommendations for Using the Machine The machine has been designed to cut metal building materials with different shapes and profiles used in workshops turner s shops and general mechanical structural work Only one operator is needed to use the machine that must stand as shown in the picture Before starting each cutting operation ensure that the part is firmly clamped in the vise and that the end is suitably supported These figures below show examples of suitable clamping of different section bars bearing in mind the cutting capacities of the machine in order to achieve a good efficiency and blade durability r Ad Ah do am Mak Do not use blades of a different size from those stated in the machine specifications the blade gets stuck in the cut release the running but ton immediately switch off the machine open the vise slowly remove the part and check that the blade or its teeth are not broken If they are broken change the tool
22. ch it as near as possible to material to be cut so that only the blade section employed in the cut is free this will prevent deflections that would excessively stress the blade Replace it Blade with major density of teeth is being used try using one with less teeth see Chapter Material classification and blade selection in the Blade Types section FAULT FAULTY CUT STREAKED CUTTING SURFACE NOISE ON GUIDE BLOCKS PROBABLE CAUSE Broken teeth Insufficient lubricating refrigerant or wrong emulsion Worn out flywheels Flywheel housing full of chips Too fast advance Poor quality blade Worn out blade or with chipped and or broken teeth Wrong tooth pitch Blade guide block too far from material to be cut Insufficient lubricating coolant or wrong emulsion Chipped bearings Worn out or damaged pads REMEDY Irregular work of the blade due to the lack of teeth can cause deflection in the cut check blade and if necessary replace it Check level of liquid in the tank Increase the flow of lubricating coolant checking that the hole and the liquid outlet pipe are not blocked Check the emulsion percentage The support and guide flange of the band are so worn out that they cannot ensure the alignment of the blade causing faulty cutting blade rolling and drawing tracks can have become tapered Replace them Clean with compressed air Decrease advance exerting less cutting pressure Adjust
23. ess Check functionality of the shields and emergency stops 6 2 Weekly Maintenance Thorough cleaning of the machine to remove shavings especially from the lubricant fluid tank Removal of pump from its housing cleaning of the suction filter and suction zone Clean the filter of the pump suction head and the suction area Use compressed air to clean the blade guides guide bearings and drain hole of the lubricating cooling Cleaning flywheel housings and blade sliding surfaces on flywheels 6 3 Monthly Maintenance Check the tightening of the motor flywheel screws Check that the blade guide bearings on the heads are perfect running condition Check the tightening of the screws of the gear motor pump and accident protection guarding 6 4 Six Monthly Maintenance Continuity test of the equipment potential protection circuit 6 5 Oils for Lubricating Coolant Considering the vast range of products on the market the user can choose the one most suited to their own requirements using as reference the type SHELL LUTEM OIL ECO THE MINIMUM PERCENTAGE OF OIL DILUTED IN WATER IS 8 10 6 6 Oil Disposal The disposal of these products is controlled by strict regulations Please see the Chapter on Machine dimensions Transport Installation in the section on Dismantling 6 7 Coolant system Cleaning the tank Use hex wrench to open the plug T the coolant to drain out Remove the grate P
24. he blade tension hand wheel remove the mobile blade guard cover open the flywheel guards and remove the old blade from the flywheels and the blade guide blocks Assemble the new blade by placing it first between the pads and then on the race of the flywheels paying particular attention to the cutting direction of the teeth Tension the blade and make sure it perfectly fits inside the seat of the flywheels Assemble the mobile blade guide end the flywheel guard and fasten it with the relative knobs Check the safety micro switch N is activated otherwise when electricity is applied the machine will not start BLADE CUTTING DIRECTION WARNING Always assemble blades having dimensions specified in this manual and for which the blade guide heads have been set otherwise see chapter on Description of the operating cycle in the section Starting up 6 ROUTINE AND SPECIAL MAINTENANCE THE MAINTENANCE JOBS ARE LISTED BELOW DIVIDED INTO DAILY WEEKLY MONTHLY AND SIX MONTHLY INTERVALS IF THE FOLLOWING OPERATIONS ARE NEGLECTED THE RESULT WILL BE PREMATURE WEAR OF THE MACHINE AND POOR PERFORMANCE 6 1 Daily maintenance General cleaning of the machine to remove accumulated shavings Clean the lubricating coolant drain hole to avoid excess fluid Top off the level of lubricating coolant Check blade for wear Rise of saw frame to top position and partial slackening of the blade to avoid useless yield sir
25. ince the aim is to obtain excellent cutting quality the various parameters such as hardness of the material shape and thickness transverse cutting section of the part to be cut selection of the type of cutting blade cutting speed and control of saw frame lowering These specifications must therefore be harmoniously combined in a single operating condition according to practical considerations and common sense so as to achieve an optimum condition that does not require countless operations to prepare the machine when there are many variations in the job to be performed The various problems that crop up from time to time will be 5275 Special manganese silicon brass G CuZn36Si1Pb1 UNI5038 620 685 375 440 320 410 265 314 solved more easily if the operator has a good knowledge of these specifications 8 1 Definition of materials The table above lists the characteristics of the materials to be cut So that the correct tools to use can be chosen 8 2 Selecting blade First of all the pitch of the teeth must be chosen in other words the number of teeth per inch 25 4 mm suitable for the material to be cut according to these criteria Parts with a thin and or variable section such as profiles pipes and plate need fine tooth so that the number of teeth used simultaneously in cutting is from 3 to 6 Parts with large transverse sections and solid sections need coarse tooth to allow for the greater volume of the sha
26. o be as close as possible to the material without interfering with the cut Tighten the hex socket screw N Reconnect the machine to power source Blade guide blocks The blade is guided by means of pads and bearings that are set in place during inspection as per the thickness of the blade with minimum play as shown in the figure In case the blade needs to be replaced make sure to always install 0 9mm thick blades for which the blade guide pad and bearings have been adjusted For saw blades clamping gaps the adjustment should be carried out as follows Note the position for pad A and bearing F are fixed and cannot be adjusted Loosen screw C nut D and setscrew D to widening the passage between the pads A and Loosen the nut G and setscrew G and rotate the shaft screw E with a flat head screwdriver to widen the passage between the bearings E and F To mount the new blade adjust the pad B to the blade then loosen the setscrew to allow a play of 0 04 mm for the movement of the saw blade Lock the nut D screw D and screw C Rotate the shaft E until the bearings rest against the blade as indicated in the figure and then secure the setscrew C and nut C BEFORE PERFORMING THE FOLLOWING OPERATIONS THE ELECTRIC POWER SUPPLY AND THE POWER CABLE MUST BE COMPLETELY DISCONNECTED 5 5 Changing the Blade To change the blade Lift the saw bow Loosen the blade with t
27. opped immediately by pressing the red mushroom button The casual or voluntary removal of the protection shield of the flywheels causes the stepping in of a micro switch that automatically stops all machine functions NOTE Resetting of machine operation after each emergency stop requires specific restart button 2 MACHINE DIMENSIONS TRANSPORT INSTALLATION DISMANTLING 2 1 Machine Dimensions 1810mm To move the machine the machine needs to be moved in its own packing use a forklift truck to move it 2 3 Minimum Requirements for Housing the Machine Main voltage and frequency must comply with the machine 5 motor requirements Environment temperature should fall within 10 C to 50 C Relative humidity cannot be over 90 2 4 Position the Machine Position the machine on a firm cement floor maintaining at the rear a minimum distance of 800 mm from the wall ensuring it is sitting on level 2 5 Instructions for Assembly of the Loose Parts and Accessories Fit the components supplied Detail 1 Mount bar stop rod Detail 2 Mount and align the roll supporting arm as per the vise table 2 6 Deactivation of Machine If the sawing machine is to be out of use for a long period it is advisable to proceed as follows 1 Detach the plug from the electric supply panel 2 Loosen blade 3 Release the saw Dow s counter balance spring 4 Empty the coolant tank 5 Carefully clean and grease the machine 6
28. ounter service Blade not perpendicular due to the excessive play between the guide pads and maladjustment of the blocks Too fast advance Worn out blade Wrong tooth pitch REMEDY Check distance between pads see Machine adjustments in the Blade Guide Blocks section extremely accurate guiding may cause cracks and breakage of the tooth Use extreme care when cleaning Approach head as near as possible to material to be cut so that only the blade section employed in the cut is free this will prevent deflections that would excessively stress the blade The back of blade rubs against the support due to deformed or poorly welded bands tapered causing cracks and swelling of the back contour Check level of liquid in the tank Increase the flow of lubricating refrigerant checking that the hole and the liquid outlet pipe are not blocked Check the emulsion percentage Replace them Adjust them see Chapter Machine adjustments in Blade guide section Check fastenings of the blade guide blocks as to the counter vice so that they are not too loose and adjust blocks vertically bring into line the position of the degrees and if necessary adjust the stop screws of the degree cuts Check and vertically re adjust the blade guide blocks reset proper side guide play see Chapter Machine adjustments In Blade guide section Decrease advance exerting less cutting pressure Adjust the braking device Approa
29. pring Washer Hex Socket Cap Screw M5x30 106 Locking Lever 1 1166 Hoseclamp jinmm 1 am EM T 108 Handle 168 Hose 5 16x40cm AE Socket Cap Screw M10x30 169 Saw Arm no SpmgWasher Jui Swish mm Gb 0 1 SwthPin 112 SprngWasher M8 6 171 Hex SocketCapScrew M4x35 2 113 Hex Socket Cap Screw M8x2O 6 172 Spring Shat 1 115 Front Ball Bearing Bracket 1 172 1 Spring Shat 1 gt 116 SetScrew Mex12 4 172H2ISetingPlate 1 117 Hex Socket Cap Screw M8x20 2 172H3 Handle J 1 118 Hex Socket Cap Screw maso 1 remu Me 2 119 Setting Bracket 1 172 H5 Bushing H3 Hex Socket Cap Sevew 66 1 yzrelAgsmgeSnat 1 121 PlastcHande 1 Jt72H7 Sping 123 CoverPlate 14 178 Spring 1 127A Side 1 74 Key lexex30 1 gt 127A 1 Spring Washer IM1O 3 175 Motor 1 128 Nut MI6x20ox8t 1 178 GearBox 1 181 Hande 2 1784 VentSeeew 1 182 Handie wheel 1 1782 Key BBB 1 gt 183 Thrust Spring Washer 10 179 SetSorew M xi2 4 134 Tension Shaft 1 181 Hex SocketCapScrew M8x2O 2 187 SetScrew M amp 3iO 2 182 FrontBladeGuard 188 Rod 1 fies RoundHeadScrew TIMER 3 189 Nut Mfex20x8t 1 fiss Bot a 140 TriggerSwitth
30. re too big bracelets chains or any other object that could get caught in the machine during operation Tie back long hair Keep the area free of equipment tools or any other object 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 All internal operations maintenance or repairs must be performed in a well lit area or where there is sufficient light from extra sources so as to avoid the risk of even slight accidents 1 2 The electrical equipment according to European Standard CENELEC EN 60204 1 The electrical equipment ensures protection against electric shock as a result of direct or indirect contact The active parts of this equipment are housed in a box to which access is limited by screws that can only be removed with a special tool the parts are fed with alternating current as low voltage 24V The equipment is protected against splashes of water and dust Protection of the system against short circuits is ensured by means of rapid fuses and grounding in the event of a motor overload protection is provided by a thermal probe In the event of a power cut the specific start up button must be reset The machine has been tested in conformity with point 20 of EN 60204 1 3 Emergencies according to European Standard CENELEC EN 60204 1 In the event of incorrect operation or of danger conditions the machine may be st
31. s HEN jeyoerg Bunsny SL malas de 184908 X H ES CES EIE 1 EE m M NE 6 H Z Loy pt T 0 016 M Ed AO oN 926 6 HZ 0 L HLZ 5 Z I HL y Z HLZ 6 6 9 0 0 Z Z1 HLZ 1 R i 9 H Z el H Z A pale Ore A 91 H Z I LI HLG HSOLGdM 24 Quantity Q 5 e c 37 WP270SH 9 INDUSTRIAL SWIVEL HEAD BANDSAW GEAR BOX EXPLODED VIEW EC DECLARATION OF CONFORMITY according to the following EC Directive Machinery Directive 2006 42 EC EMC Directive 2004 108 EC LVD Directive 2006 95 EC RoHs Directive 2002 95 EC The undersigned Kuo Chuan Lin _ representing Way Train Industries Co Ltd No 1008 Hou Chuang Rd Pei Tun Chu Taichung Taiwan R O C manufacturer declares that the machine described hereafter Bandsaw for metalworking Model WP 270S WP 270SH Provided that it is used and maintained in accordance with the generally accepted codes of good practice and the recommendations of the instructions manual meets the essential safety and health requirements of the Machinery Directive EMC directive LVD Directive and RoHs Directive For the most specific risks of this machine safety and compliance with the essential requirements of the Directive has been based on elements of The European Standard EN 60204 1 2007 Safety for the electrical equipment of machinery The European Standard EN 55011 199
32. the braking device Use a superior quality blade Replace it Blade used probably has too large teeth use one with more teeth see Material classification and blade selection in the Blade Types section Approach it as near as possible to material to be cut so that only the blade section employed in the cut is free this will prevent deflections that would excessively stress the blade Check level of liquid in the tank Increase the flow of lubricating coolant checking that the hole and the liquid outlet pipe are not blocked Check the emulsion percentage Dirt and or chips between blade and guide bearings Replace them Replace them PART LIST BE sem see omr see ow X Base RightPart 1 154 VseTablg 10 2 Washer M O 4 55 BarStopRod 1 3 HexCapBot MtOx20 4 186 Bracket pp 1 D UEUD RE GA 5 Washer M8x18x2 58 Washer a 8x2 6 Hex Cap Bolt M8x16 S Spring Washer 7 Base eo Gap Bot ie 114 8 Base LeftPart 1 je Rd 1 10 9 Hex SocketCapScrew M8x20 2 62 Nut 6 10 11 Hex SocketCapScrew M8x20 2 642 ScadePont 13 Washer M8x18x2 66 Anti Dust Cover M30 5 Supporting O Ball Bearing 52008 2 15 Roller Stand Bracket 1 je Nt mo 2 16 Washer M10x21x2 2 69 HexCapBot M1Ox25 1 18 Hex CapBolt M1Ox20 2 70 SpimgHook 10 19 Roler 1 72 StarWasher M30 1 gt 19 1 RollerShaft 11178 Int IIM
33. utting pressure Thick and or blue chips indicate overload of the blade 8 5 Blade running in When cutting for the first time it is good practice to run in the tool making a series of cuts at a low advance speed 30 35 cm min on material of average dimensions with respect to the cutting capacity and solid section of normal steel with R 410 510 N mm Generously spraying the cutting area with lubricating coolant 8 6 Blade structure Bi metal blades are the most commonly used They consist of a silicon steel blade backing by a laser welded high speed steel HHS cutting edge The type of stocks are classified in M2 M42 M51 and differ from each other because of their major hardness due to the increasing percentage of Cobalt Cc and molybdenum Mo contained in the metal alloy 8 7 Blade type They differ essentially in their constructive characteristics such as Shape and cutting angle of tooth Pitch Set Shape and angle of tooth REGULAR TOOTH O rake and constant pitch Most common form for transversal or inclined cutting of solid small and average cross sections or pipes in laminated mild steel and gray iron or general metal POSITIVE RAKE TOOTH 9 10 positive rake and constant pitch positive Particular use for crosswise or inclined cuts in solid sections or large pipes but above all harder materials highly alloyed and stainless steels special bronze and forge pig iron COMBO T
34. vings and better tooth penetration Parts made of soft material or plastic light alloys mild bronze Teflon wood etc also require widely spaced tooth Pieces cut in bundles require combo tooth design 8 3 Teeth pitch As already stated this depends on the following factors Hardness of the material Dimensions of the section Wall thickness BLADE TEETH SELECTION TABLE 7 CONTINUOUS Z COMBO THICKNESS MM TOOTH DESIGN TOOTH DESIGN TILL 1 5 10 14 FROMTITOS 8 S JJ FROM2TO3 6 6 10 FROM3TO5 6 8S8 FROM4TO6 89 46 MORE THAN 6 S THICKNESS Z CONTINUOUS Z COMBO a NE ms sne FROM 40 TO 80 MORE THAN 90 8 4 Cutting and advance speed The cutting speed m min and the advance speed cm2min area traveled by the disk teeth when removing shavings are limited by the development of heat close to the tips of the teeth The cutting speed is ciue to the resistance of the material R N mm to its hardness HRC and to the dimensions of the widest section Too high an advance speed lowering of the saw frame tends to cause the disk to deviate from the ideal cutting path producing non rectilinear cuts on bath the vertical and the horizontal plane The best combination of these two parameters can be seen directly examining the chips Long spiral shaped chips indicate ideal cutting Very fine or pulverized chips indicate lack of feed and or c
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