Angle Cutting Horizontal Metal Band Sawing Machine

Instruction Manual

ModelGB4035H

Specification90deg Φ13 322520 1532 x 11 13245deg Φ11 131611 1316 x 9 2664

Serial No

Contents

I Main applicationhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip1

II Main technical parametershelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip1

III Machine tool lifting and installationhelliphelliphelliphelliphelliphelliphelliphellip1

IV Main structurehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip3

V Driving systemhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip4

VI Hydraulic transmission systemhelliphelliphelliphelliphelliphelliphelliphelliphelliphellip6

VII Electrical control systemhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip8

VIII Lubrication and cooling systemhelliphelliphelliphelliphelliphelliphelliphelliphellip12

IX Operating systemhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip14

X Regulation of Machine Toolhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip14

XI Common Faults and Removal Solutionshelliphelliphelliphelliphelliphellip18

XII Appendix tablehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip19

Warning1 Never exceed the scope and application of the machine

2 Never use machine before reading the Instruction Manual

3The operator must be trained professionally having capacity to complete various operations safely and to prevent the injury and damage by improper operation for the machine

4Users must strictly follow the instruction manual for the correct installation and the operation provide appropriate and clean operational areas without any prejudice to the operator for the safe operation and routine maintenance

5 The operator must be regulated by the Instruction Manual and training requirements and do maintenance for machine periodically to ensure the safety

6The operator must have security guards working conditions and regularly checks their integrity never arbitrary remove security guards If necessary protection-boom should be set up around the machine

7 Defensive cover must be covered all before operation and adjust saw blade transferable protection as close as possible to the work piece Never open any protective mask during operation 8Check the machine stopped before replacing Band Saw and the round cocoon protective masks and check whether the support firmly reliable Protective gloves must be carried to guard against the pricks and hurting when disassemble saw blade 9 During operation any part of the body never contact with the band saws or enter the processing zones never restock the jammed or cut off work piece 10Never operate or maintain running machine with gloves or loose clothing 11Before sawing must confirm the work piece is clamped firmly and to ensure that the work piece at clamping state during the whole process of sawing Do not loose the work piece until saw blade stopped

12Enough support should be provide to long and heavy materialsrsquomerging and cutting to avoid the work piece drop in cutting that may lead the cutting machine

overturning Use feed and access information planes when cutting longer material

13 Sure to cut off power before adjusting repairing maintenance and cleaning the

machine especially in the maintenance of electrical cut off power to prevent electric

shock accidents

14Machine must stop before varying speed

15 Be sure the machine stopped when adjusting the distance of saw guide arm and

fasten Hand Wheel after adjusting

16Machine power for three-phase alternating current voltage fluctuations in the

value of less than 10 Set up a separate power supply according to the rated

capacity Earth leakage protection devices Tt is prohibited to share wiring with the

other equipment which may cause voltage fluctuations or misuse

17 Machine must completely on the ground good and reliable

18 If have any accident please press the emergency stop button

19 Cooling liquid may damage human skin be careful when cleaning and operation

It cannot drop into the underground should be dealt with environmental

requirements To prevent coolant splash in processing users can set up protective

railings plate

20 In cutting chip combustible materials (such as magnesium titanium etc)

prohibit pyrotechnics and should take fire measures

21 Never sawing inflammable material in powder (such as carbon rod) to prevent

fire or explosion

(Note the technology date is subject to change)

1

1

1

I Main application

Apart from the functions of vertical sawing the whole saw frame rotating band sawing machine can implement material clockwise 0~45degof oblique cutting the fixed jaw and the material does not need to change for the sake of saving space It is applicable to channel steel H steel and other heterosexual steel as well as plate and metal materials II Main technical parameters

1 Main specifications

Main Technical Parameters Table I

III Machine tool lifting and installation

1 Lifting

When transporting the machine tools use the lifting equipment to the greatest extent The connection method of the steel cable during lifting is shown in Figure 1 Soft objects such as wood blocks and rubber should be placed where the steel cable may touch the parts whereby avoiding the damage to the parts and the paint 2 Unpacking

The Packing List should be checked for the quantity of the goods when unpacking 3 Installation

The machine tools should be installed in the where is free of obvious seismic source and the foundation of concrete structure can be adopted the ground should be flat there should be enough space around the machine easy to install debug maintain and convenient for other operations etc The level gauge is placed on the middle bed surface of the clamping port and the machine tool mat (purchased by the customer) or pad iron with sawing machine cabinet base shall be adjusted respectively along the longitudinal and transverse direction Tighten the anchor bolts when the sawing machine is in horizontal level refer to figure 2

Type of sawing machine GB4035H

Range of saw cutting (in)90deg Φ13 322520 1532 x 11 13245deg Φ11 131611 1316 x 9 2664

Specification of saw blade length x width x thick 185 364 x 1 1132 x 364Cutting speed 905 33641535 7162519

11163307 332Feed speed inmin Stepless speed controlPower of main motor K W 22KWMotor power of oil pump KW 1120Water pump power KW 125Physical dimension (length X width X height ) of the machine tool 98 2764 x 59 116 x 55 18

2

Figure 1 Hoisting Drawing of Machine Tool

Figure 2 Schematic Diagram of Horizontal

Adjustment of Machine Tool

Figure 3 Schematic Diagram of

Foot Margin

IV Main structure

Anchor Bolt

A-A

3

The inner cavity of the base has large space the front side is the hydraulic oil tank the back side is the hydraulic system and the right side is the coolant tank Lathe bed bearing seat fixed on the base and lathe bed can rotate 0~45deg and the bed body is equipped with jaw clamping screw and slide block the left with the clamping cylinder and the hand wheel The tightening and loosening the work-piece can be achieved by rotary valve when the screw rod turns the left clamp port away from the work-piece 039-098in The back side is equipped with a feeding mechanism the front side is equipped with a feeding plate the saw beam rotates around a supporting shaft the left side of the saw beam is equipped with a tension seat a driven wheel and the right side with a worm gear case The motor behind the worm gear case drives the driving wheels to rotate and then drives the saw blade around the active and driven wheels for cutting motion and the cutting accuracy is adjusted by the middle guide arm and the guide head The motions of sawing machine is controlled by hydraulic and electric system

Figure 4 Drawing of Machine Tool Structure

1 Electrical box 2 Driven wheel 3 Wheel cover bracket 4 Saw beam 5 Guide section 6 Lathe bed

7 Driving wheel 8 Belt wheel 9 Surrounding edge 10 Base 11 Liquid level and temperature gauge

12 Tank cleaning cover 13 Side-mount oil filler

1 Guiding device

The left and right guide arms installed on the beam move along the dovetail groove and adjust the spacing between the guide arms and the workpiece 079-197in The guide device is used to change the angle relative to the lathe bed which the saw blade perpendicular to the bed surface the left and right guide heads are provided with a set of guide wheels and wear resistant alloy guide blocks 2 Tensioning device

The tensioning device consists of a tensioning seat a tensioning slider a screw rod etc when a saw

4

（ ）

blade is tensed saw blade can be tightened by using the hand wheel to rotate the screw rod clockwise If the sawing machine blocks for a long time turn the hand wheel counterclockwise to loosen the saw blade or replace the saw blade 3 Feed motion of saw blade

The hydraulic circulation system consists of lifting cylinder and throttle valve which controls the descending speed of saw beams to control the feed (stepless speed regulation) of the saw blade 4 Rotation of copper wire brush

Rotate along the direction of the saw at the place where the saw blade is sheared and clean by water pump cooling fluid to remove the sawdust on the saw blade V Driving system 1 Rolling Bearing Location Drawing Schematic Diagram of Guide Head Bearing Structure Schematic Diagram of Angular Bearing

Schematic Diagram of Driven Wheel Bearing

1 Bearing of driven wheel 2Lock nut retaining washer 3Gland of driven wheel

4Spacer bushing

5 Driven wheel 6Tensioning wheel 7Tensioning socket 8Tensioning slider 9Revolver gasket

10 Tensioning seat clamp plate 11Hollow bolt

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

Contents

I Main applicationhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip1

II Main technical parametershelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip1

III Machine tool lifting and installationhelliphelliphelliphelliphelliphelliphelliphellip1

IV Main structurehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip3

V Driving systemhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip4

VI Hydraulic transmission systemhelliphelliphelliphelliphelliphelliphelliphelliphelliphellip6

VII Electrical control systemhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip8

VIII Lubrication and cooling systemhelliphelliphelliphelliphelliphelliphelliphelliphellip12

IX Operating systemhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip14

X Regulation of Machine Toolhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip14

XI Common Faults and Removal Solutionshelliphelliphelliphelliphelliphellip18

XII Appendix tablehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip19

Warning1 Never exceed the scope and application of the machine

2 Never use machine before reading the Instruction Manual

3The operator must be trained professionally having capacity to complete various operations safely and to prevent the injury and damage by improper operation for the machine

4Users must strictly follow the instruction manual for the correct installation and the operation provide appropriate and clean operational areas without any prejudice to the operator for the safe operation and routine maintenance

5 The operator must be regulated by the Instruction Manual and training requirements and do maintenance for machine periodically to ensure the safety

6The operator must have security guards working conditions and regularly checks their integrity never arbitrary remove security guards If necessary protection-boom should be set up around the machine

7 Defensive cover must be covered all before operation and adjust saw blade transferable protection as close as possible to the work piece Never open any protective mask during operation 8Check the machine stopped before replacing Band Saw and the round cocoon protective masks and check whether the support firmly reliable Protective gloves must be carried to guard against the pricks and hurting when disassemble saw blade 9 During operation any part of the body never contact with the band saws or enter the processing zones never restock the jammed or cut off work piece 10Never operate or maintain running machine with gloves or loose clothing 11Before sawing must confirm the work piece is clamped firmly and to ensure that the work piece at clamping state during the whole process of sawing Do not loose the work piece until saw blade stopped

12Enough support should be provide to long and heavy materialsrsquomerging and cutting to avoid the work piece drop in cutting that may lead the cutting machine

overturning Use feed and access information planes when cutting longer material

13 Sure to cut off power before adjusting repairing maintenance and cleaning the

machine especially in the maintenance of electrical cut off power to prevent electric

shock accidents

14Machine must stop before varying speed

15 Be sure the machine stopped when adjusting the distance of saw guide arm and

fasten Hand Wheel after adjusting

16Machine power for three-phase alternating current voltage fluctuations in the

value of less than 10 Set up a separate power supply according to the rated

capacity Earth leakage protection devices Tt is prohibited to share wiring with the

other equipment which may cause voltage fluctuations or misuse

17 Machine must completely on the ground good and reliable

18 If have any accident please press the emergency stop button

19 Cooling liquid may damage human skin be careful when cleaning and operation

It cannot drop into the underground should be dealt with environmental

requirements To prevent coolant splash in processing users can set up protective

railings plate

20 In cutting chip combustible materials (such as magnesium titanium etc)

prohibit pyrotechnics and should take fire measures

21 Never sawing inflammable material in powder (such as carbon rod) to prevent

fire or explosion

(Note the technology date is subject to change)

1

1

1

I Main application

Apart from the functions of vertical sawing the whole saw frame rotating band sawing machine can implement material clockwise 0~45degof oblique cutting the fixed jaw and the material does not need to change for the sake of saving space It is applicable to channel steel H steel and other heterosexual steel as well as plate and metal materials II Main technical parameters

1 Main specifications

Main Technical Parameters Table I

III Machine tool lifting and installation

1 Lifting

When transporting the machine tools use the lifting equipment to the greatest extent The connection method of the steel cable during lifting is shown in Figure 1 Soft objects such as wood blocks and rubber should be placed where the steel cable may touch the parts whereby avoiding the damage to the parts and the paint 2 Unpacking

The Packing List should be checked for the quantity of the goods when unpacking 3 Installation

The machine tools should be installed in the where is free of obvious seismic source and the foundation of concrete structure can be adopted the ground should be flat there should be enough space around the machine easy to install debug maintain and convenient for other operations etc The level gauge is placed on the middle bed surface of the clamping port and the machine tool mat (purchased by the customer) or pad iron with sawing machine cabinet base shall be adjusted respectively along the longitudinal and transverse direction Tighten the anchor bolts when the sawing machine is in horizontal level refer to figure 2

Type of sawing machine GB4035H

Range of saw cutting (in)90deg Φ13 322520 1532 x 11 13245deg Φ11 131611 1316 x 9 2664

Specification of saw blade length x width x thick 185 364 x 1 1132 x 364Cutting speed 905 33641535 7162519

11163307 332Feed speed inmin Stepless speed controlPower of main motor K W 22KWMotor power of oil pump KW 1120Water pump power KW 125Physical dimension (length X width X height ) of the machine tool 98 2764 x 59 116 x 55 18

2

Figure 1 Hoisting Drawing of Machine Tool

Figure 2 Schematic Diagram of Horizontal

Adjustment of Machine Tool

Figure 3 Schematic Diagram of

Foot Margin

IV Main structure

Anchor Bolt

A-A

3

The inner cavity of the base has large space the front side is the hydraulic oil tank the back side is the hydraulic system and the right side is the coolant tank Lathe bed bearing seat fixed on the base and lathe bed can rotate 0~45deg and the bed body is equipped with jaw clamping screw and slide block the left with the clamping cylinder and the hand wheel The tightening and loosening the work-piece can be achieved by rotary valve when the screw rod turns the left clamp port away from the work-piece 039-098in The back side is equipped with a feeding mechanism the front side is equipped with a feeding plate the saw beam rotates around a supporting shaft the left side of the saw beam is equipped with a tension seat a driven wheel and the right side with a worm gear case The motor behind the worm gear case drives the driving wheels to rotate and then drives the saw blade around the active and driven wheels for cutting motion and the cutting accuracy is adjusted by the middle guide arm and the guide head The motions of sawing machine is controlled by hydraulic and electric system

Figure 4 Drawing of Machine Tool Structure

1 Electrical box 2 Driven wheel 3 Wheel cover bracket 4 Saw beam 5 Guide section 6 Lathe bed

7 Driving wheel 8 Belt wheel 9 Surrounding edge 10 Base 11 Liquid level and temperature gauge

12 Tank cleaning cover 13 Side-mount oil filler

1 Guiding device

The left and right guide arms installed on the beam move along the dovetail groove and adjust the spacing between the guide arms and the workpiece 079-197in The guide device is used to change the angle relative to the lathe bed which the saw blade perpendicular to the bed surface the left and right guide heads are provided with a set of guide wheels and wear resistant alloy guide blocks 2 Tensioning device

The tensioning device consists of a tensioning seat a tensioning slider a screw rod etc when a saw

4

（ ）

blade is tensed saw blade can be tightened by using the hand wheel to rotate the screw rod clockwise If the sawing machine blocks for a long time turn the hand wheel counterclockwise to loosen the saw blade or replace the saw blade 3 Feed motion of saw blade

The hydraulic circulation system consists of lifting cylinder and throttle valve which controls the descending speed of saw beams to control the feed (stepless speed regulation) of the saw blade 4 Rotation of copper wire brush

Rotate along the direction of the saw at the place where the saw blade is sheared and clean by water pump cooling fluid to remove the sawdust on the saw blade V Driving system 1 Rolling Bearing Location Drawing Schematic Diagram of Guide Head Bearing Structure Schematic Diagram of Angular Bearing

Schematic Diagram of Driven Wheel Bearing

1 Bearing of driven wheel 2Lock nut retaining washer 3Gland of driven wheel

4Spacer bushing

5 Driven wheel 6Tensioning wheel 7Tensioning socket 8Tensioning slider 9Revolver gasket

10 Tensioning seat clamp plate 11Hollow bolt

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

IX Operating systemhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip14

X Regulation of Machine Toolhelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip14

XI Common Faults and Removal Solutionshelliphelliphelliphelliphelliphellip18

XII Appendix tablehelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphelliphellip19

Warning1 Never exceed the scope and application of the machine

2 Never use machine before reading the Instruction Manual

3The operator must be trained professionally having capacity to complete various operations safely and to prevent the injury and damage by improper operation for the machine

4Users must strictly follow the instruction manual for the correct installation and the operation provide appropriate and clean operational areas without any prejudice to the operator for the safe operation and routine maintenance

5 The operator must be regulated by the Instruction Manual and training requirements and do maintenance for machine periodically to ensure the safety

6The operator must have security guards working conditions and regularly checks their integrity never arbitrary remove security guards If necessary protection-boom should be set up around the machine

7 Defensive cover must be covered all before operation and adjust saw blade transferable protection as close as possible to the work piece Never open any protective mask during operation 8Check the machine stopped before replacing Band Saw and the round cocoon protective masks and check whether the support firmly reliable Protective gloves must be carried to guard against the pricks and hurting when disassemble saw blade 9 During operation any part of the body never contact with the band saws or enter the processing zones never restock the jammed or cut off work piece 10Never operate or maintain running machine with gloves or loose clothing 11Before sawing must confirm the work piece is clamped firmly and to ensure that the work piece at clamping state during the whole process of sawing Do not loose the work piece until saw blade stopped

12Enough support should be provide to long and heavy materialsrsquomerging and cutting to avoid the work piece drop in cutting that may lead the cutting machine

overturning Use feed and access information planes when cutting longer material

13 Sure to cut off power before adjusting repairing maintenance and cleaning the

machine especially in the maintenance of electrical cut off power to prevent electric

shock accidents

14Machine must stop before varying speed

15 Be sure the machine stopped when adjusting the distance of saw guide arm and

fasten Hand Wheel after adjusting

16Machine power for three-phase alternating current voltage fluctuations in the

value of less than 10 Set up a separate power supply according to the rated

capacity Earth leakage protection devices Tt is prohibited to share wiring with the

other equipment which may cause voltage fluctuations or misuse

17 Machine must completely on the ground good and reliable

18 If have any accident please press the emergency stop button

19 Cooling liquid may damage human skin be careful when cleaning and operation

It cannot drop into the underground should be dealt with environmental

requirements To prevent coolant splash in processing users can set up protective

railings plate

20 In cutting chip combustible materials (such as magnesium titanium etc)

prohibit pyrotechnics and should take fire measures

21 Never sawing inflammable material in powder (such as carbon rod) to prevent

fire or explosion

(Note the technology date is subject to change)

1

1

1

I Main application

Apart from the functions of vertical sawing the whole saw frame rotating band sawing machine can implement material clockwise 0~45degof oblique cutting the fixed jaw and the material does not need to change for the sake of saving space It is applicable to channel steel H steel and other heterosexual steel as well as plate and metal materials II Main technical parameters

1 Main specifications

Main Technical Parameters Table I

III Machine tool lifting and installation

1 Lifting

When transporting the machine tools use the lifting equipment to the greatest extent The connection method of the steel cable during lifting is shown in Figure 1 Soft objects such as wood blocks and rubber should be placed where the steel cable may touch the parts whereby avoiding the damage to the parts and the paint 2 Unpacking

The Packing List should be checked for the quantity of the goods when unpacking 3 Installation

The machine tools should be installed in the where is free of obvious seismic source and the foundation of concrete structure can be adopted the ground should be flat there should be enough space around the machine easy to install debug maintain and convenient for other operations etc The level gauge is placed on the middle bed surface of the clamping port and the machine tool mat (purchased by the customer) or pad iron with sawing machine cabinet base shall be adjusted respectively along the longitudinal and transverse direction Tighten the anchor bolts when the sawing machine is in horizontal level refer to figure 2

Type of sawing machine GB4035H

Range of saw cutting (in)90deg Φ13 322520 1532 x 11 13245deg Φ11 131611 1316 x 9 2664

Specification of saw blade length x width x thick 185 364 x 1 1132 x 364Cutting speed 905 33641535 7162519

11163307 332Feed speed inmin Stepless speed controlPower of main motor K W 22KWMotor power of oil pump KW 1120Water pump power KW 125Physical dimension (length X width X height ) of the machine tool 98 2764 x 59 116 x 55 18

2

Figure 1 Hoisting Drawing of Machine Tool

Figure 2 Schematic Diagram of Horizontal

Adjustment of Machine Tool

Figure 3 Schematic Diagram of

Foot Margin

IV Main structure

Anchor Bolt

A-A

3

The inner cavity of the base has large space the front side is the hydraulic oil tank the back side is the hydraulic system and the right side is the coolant tank Lathe bed bearing seat fixed on the base and lathe bed can rotate 0~45deg and the bed body is equipped with jaw clamping screw and slide block the left with the clamping cylinder and the hand wheel The tightening and loosening the work-piece can be achieved by rotary valve when the screw rod turns the left clamp port away from the work-piece 039-098in The back side is equipped with a feeding mechanism the front side is equipped with a feeding plate the saw beam rotates around a supporting shaft the left side of the saw beam is equipped with a tension seat a driven wheel and the right side with a worm gear case The motor behind the worm gear case drives the driving wheels to rotate and then drives the saw blade around the active and driven wheels for cutting motion and the cutting accuracy is adjusted by the middle guide arm and the guide head The motions of sawing machine is controlled by hydraulic and electric system

Figure 4 Drawing of Machine Tool Structure

1 Electrical box 2 Driven wheel 3 Wheel cover bracket 4 Saw beam 5 Guide section 6 Lathe bed

7 Driving wheel 8 Belt wheel 9 Surrounding edge 10 Base 11 Liquid level and temperature gauge

12 Tank cleaning cover 13 Side-mount oil filler

1 Guiding device

The left and right guide arms installed on the beam move along the dovetail groove and adjust the spacing between the guide arms and the workpiece 079-197in The guide device is used to change the angle relative to the lathe bed which the saw blade perpendicular to the bed surface the left and right guide heads are provided with a set of guide wheels and wear resistant alloy guide blocks 2 Tensioning device

The tensioning device consists of a tensioning seat a tensioning slider a screw rod etc when a saw

4

（ ）

blade is tensed saw blade can be tightened by using the hand wheel to rotate the screw rod clockwise If the sawing machine blocks for a long time turn the hand wheel counterclockwise to loosen the saw blade or replace the saw blade 3 Feed motion of saw blade

The hydraulic circulation system consists of lifting cylinder and throttle valve which controls the descending speed of saw beams to control the feed (stepless speed regulation) of the saw blade 4 Rotation of copper wire brush

Rotate along the direction of the saw at the place where the saw blade is sheared and clean by water pump cooling fluid to remove the sawdust on the saw blade V Driving system 1 Rolling Bearing Location Drawing Schematic Diagram of Guide Head Bearing Structure Schematic Diagram of Angular Bearing

Schematic Diagram of Driven Wheel Bearing

1 Bearing of driven wheel 2Lock nut retaining washer 3Gland of driven wheel

4Spacer bushing

5 Driven wheel 6Tensioning wheel 7Tensioning socket 8Tensioning slider 9Revolver gasket

10 Tensioning seat clamp plate 11Hollow bolt

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

Warning1 Never exceed the scope and application of the machine

2 Never use machine before reading the Instruction Manual

3The operator must be trained professionally having capacity to complete various operations safely and to prevent the injury and damage by improper operation for the machine

4Users must strictly follow the instruction manual for the correct installation and the operation provide appropriate and clean operational areas without any prejudice to the operator for the safe operation and routine maintenance

5 The operator must be regulated by the Instruction Manual and training requirements and do maintenance for machine periodically to ensure the safety

6The operator must have security guards working conditions and regularly checks their integrity never arbitrary remove security guards If necessary protection-boom should be set up around the machine

7 Defensive cover must be covered all before operation and adjust saw blade transferable protection as close as possible to the work piece Never open any protective mask during operation 8Check the machine stopped before replacing Band Saw and the round cocoon protective masks and check whether the support firmly reliable Protective gloves must be carried to guard against the pricks and hurting when disassemble saw blade 9 During operation any part of the body never contact with the band saws or enter the processing zones never restock the jammed or cut off work piece 10Never operate or maintain running machine with gloves or loose clothing 11Before sawing must confirm the work piece is clamped firmly and to ensure that the work piece at clamping state during the whole process of sawing Do not loose the work piece until saw blade stopped

12Enough support should be provide to long and heavy materialsrsquomerging and cutting to avoid the work piece drop in cutting that may lead the cutting machine

overturning Use feed and access information planes when cutting longer material

13 Sure to cut off power before adjusting repairing maintenance and cleaning the

machine especially in the maintenance of electrical cut off power to prevent electric

shock accidents

14Machine must stop before varying speed

15 Be sure the machine stopped when adjusting the distance of saw guide arm and

fasten Hand Wheel after adjusting

16Machine power for three-phase alternating current voltage fluctuations in the

value of less than 10 Set up a separate power supply according to the rated

capacity Earth leakage protection devices Tt is prohibited to share wiring with the

other equipment which may cause voltage fluctuations or misuse

17 Machine must completely on the ground good and reliable

18 If have any accident please press the emergency stop button

19 Cooling liquid may damage human skin be careful when cleaning and operation

It cannot drop into the underground should be dealt with environmental

requirements To prevent coolant splash in processing users can set up protective

railings plate

20 In cutting chip combustible materials (such as magnesium titanium etc)

prohibit pyrotechnics and should take fire measures

21 Never sawing inflammable material in powder (such as carbon rod) to prevent

fire or explosion

(Note the technology date is subject to change)

1

1

1

I Main application

Apart from the functions of vertical sawing the whole saw frame rotating band sawing machine can implement material clockwise 0~45degof oblique cutting the fixed jaw and the material does not need to change for the sake of saving space It is applicable to channel steel H steel and other heterosexual steel as well as plate and metal materials II Main technical parameters

1 Main specifications

Main Technical Parameters Table I

III Machine tool lifting and installation

1 Lifting

When transporting the machine tools use the lifting equipment to the greatest extent The connection method of the steel cable during lifting is shown in Figure 1 Soft objects such as wood blocks and rubber should be placed where the steel cable may touch the parts whereby avoiding the damage to the parts and the paint 2 Unpacking

The Packing List should be checked for the quantity of the goods when unpacking 3 Installation

The machine tools should be installed in the where is free of obvious seismic source and the foundation of concrete structure can be adopted the ground should be flat there should be enough space around the machine easy to install debug maintain and convenient for other operations etc The level gauge is placed on the middle bed surface of the clamping port and the machine tool mat (purchased by the customer) or pad iron with sawing machine cabinet base shall be adjusted respectively along the longitudinal and transverse direction Tighten the anchor bolts when the sawing machine is in horizontal level refer to figure 2

Type of sawing machine GB4035H

Range of saw cutting (in)90deg Φ13 322520 1532 x 11 13245deg Φ11 131611 1316 x 9 2664

Specification of saw blade length x width x thick 185 364 x 1 1132 x 364Cutting speed 905 33641535 7162519

11163307 332Feed speed inmin Stepless speed controlPower of main motor K W 22KWMotor power of oil pump KW 1120Water pump power KW 125Physical dimension (length X width X height ) of the machine tool 98 2764 x 59 116 x 55 18

2

Figure 1 Hoisting Drawing of Machine Tool

Figure 2 Schematic Diagram of Horizontal

Adjustment of Machine Tool

Figure 3 Schematic Diagram of

Foot Margin

IV Main structure

Anchor Bolt

A-A

3

The inner cavity of the base has large space the front side is the hydraulic oil tank the back side is the hydraulic system and the right side is the coolant tank Lathe bed bearing seat fixed on the base and lathe bed can rotate 0~45deg and the bed body is equipped with jaw clamping screw and slide block the left with the clamping cylinder and the hand wheel The tightening and loosening the work-piece can be achieved by rotary valve when the screw rod turns the left clamp port away from the work-piece 039-098in The back side is equipped with a feeding mechanism the front side is equipped with a feeding plate the saw beam rotates around a supporting shaft the left side of the saw beam is equipped with a tension seat a driven wheel and the right side with a worm gear case The motor behind the worm gear case drives the driving wheels to rotate and then drives the saw blade around the active and driven wheels for cutting motion and the cutting accuracy is adjusted by the middle guide arm and the guide head The motions of sawing machine is controlled by hydraulic and electric system

Figure 4 Drawing of Machine Tool Structure

1 Electrical box 2 Driven wheel 3 Wheel cover bracket 4 Saw beam 5 Guide section 6 Lathe bed

7 Driving wheel 8 Belt wheel 9 Surrounding edge 10 Base 11 Liquid level and temperature gauge

12 Tank cleaning cover 13 Side-mount oil filler

1 Guiding device

The left and right guide arms installed on the beam move along the dovetail groove and adjust the spacing between the guide arms and the workpiece 079-197in The guide device is used to change the angle relative to the lathe bed which the saw blade perpendicular to the bed surface the left and right guide heads are provided with a set of guide wheels and wear resistant alloy guide blocks 2 Tensioning device

The tensioning device consists of a tensioning seat a tensioning slider a screw rod etc when a saw

4

（ ）

blade is tensed saw blade can be tightened by using the hand wheel to rotate the screw rod clockwise If the sawing machine blocks for a long time turn the hand wheel counterclockwise to loosen the saw blade or replace the saw blade 3 Feed motion of saw blade

The hydraulic circulation system consists of lifting cylinder and throttle valve which controls the descending speed of saw beams to control the feed (stepless speed regulation) of the saw blade 4 Rotation of copper wire brush

Rotate along the direction of the saw at the place where the saw blade is sheared and clean by water pump cooling fluid to remove the sawdust on the saw blade V Driving system 1 Rolling Bearing Location Drawing Schematic Diagram of Guide Head Bearing Structure Schematic Diagram of Angular Bearing

Schematic Diagram of Driven Wheel Bearing

1 Bearing of driven wheel 2Lock nut retaining washer 3Gland of driven wheel

4Spacer bushing

5 Driven wheel 6Tensioning wheel 7Tensioning socket 8Tensioning slider 9Revolver gasket

10 Tensioning seat clamp plate 11Hollow bolt

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

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7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

overturning Use feed and access information planes when cutting longer material

13 Sure to cut off power before adjusting repairing maintenance and cleaning the

machine especially in the maintenance of electrical cut off power to prevent electric

shock accidents

14Machine must stop before varying speed

15 Be sure the machine stopped when adjusting the distance of saw guide arm and

fasten Hand Wheel after adjusting

16Machine power for three-phase alternating current voltage fluctuations in the

value of less than 10 Set up a separate power supply according to the rated

capacity Earth leakage protection devices Tt is prohibited to share wiring with the

other equipment which may cause voltage fluctuations or misuse

17 Machine must completely on the ground good and reliable

18 If have any accident please press the emergency stop button

19 Cooling liquid may damage human skin be careful when cleaning and operation

It cannot drop into the underground should be dealt with environmental

requirements To prevent coolant splash in processing users can set up protective

railings plate

20 In cutting chip combustible materials (such as magnesium titanium etc)

prohibit pyrotechnics and should take fire measures

21 Never sawing inflammable material in powder (such as carbon rod) to prevent

fire or explosion

(Note the technology date is subject to change)

1

1

1

I Main application

Apart from the functions of vertical sawing the whole saw frame rotating band sawing machine can implement material clockwise 0~45degof oblique cutting the fixed jaw and the material does not need to change for the sake of saving space It is applicable to channel steel H steel and other heterosexual steel as well as plate and metal materials II Main technical parameters

1 Main specifications

Main Technical Parameters Table I

III Machine tool lifting and installation

1 Lifting

When transporting the machine tools use the lifting equipment to the greatest extent The connection method of the steel cable during lifting is shown in Figure 1 Soft objects such as wood blocks and rubber should be placed where the steel cable may touch the parts whereby avoiding the damage to the parts and the paint 2 Unpacking

The Packing List should be checked for the quantity of the goods when unpacking 3 Installation

The machine tools should be installed in the where is free of obvious seismic source and the foundation of concrete structure can be adopted the ground should be flat there should be enough space around the machine easy to install debug maintain and convenient for other operations etc The level gauge is placed on the middle bed surface of the clamping port and the machine tool mat (purchased by the customer) or pad iron with sawing machine cabinet base shall be adjusted respectively along the longitudinal and transverse direction Tighten the anchor bolts when the sawing machine is in horizontal level refer to figure 2

Type of sawing machine GB4035H

Range of saw cutting (in)90deg Φ13 322520 1532 x 11 13245deg Φ11 131611 1316 x 9 2664

Specification of saw blade length x width x thick 185 364 x 1 1132 x 364Cutting speed 905 33641535 7162519

11163307 332Feed speed inmin Stepless speed controlPower of main motor K W 22KWMotor power of oil pump KW 1120Water pump power KW 125Physical dimension (length X width X height ) of the machine tool 98 2764 x 59 116 x 55 18

2

Figure 1 Hoisting Drawing of Machine Tool

Figure 2 Schematic Diagram of Horizontal

Adjustment of Machine Tool

Figure 3 Schematic Diagram of

Foot Margin

IV Main structure

Anchor Bolt

A-A

3

The inner cavity of the base has large space the front side is the hydraulic oil tank the back side is the hydraulic system and the right side is the coolant tank Lathe bed bearing seat fixed on the base and lathe bed can rotate 0~45deg and the bed body is equipped with jaw clamping screw and slide block the left with the clamping cylinder and the hand wheel The tightening and loosening the work-piece can be achieved by rotary valve when the screw rod turns the left clamp port away from the work-piece 039-098in The back side is equipped with a feeding mechanism the front side is equipped with a feeding plate the saw beam rotates around a supporting shaft the left side of the saw beam is equipped with a tension seat a driven wheel and the right side with a worm gear case The motor behind the worm gear case drives the driving wheels to rotate and then drives the saw blade around the active and driven wheels for cutting motion and the cutting accuracy is adjusted by the middle guide arm and the guide head The motions of sawing machine is controlled by hydraulic and electric system

Figure 4 Drawing of Machine Tool Structure

1 Electrical box 2 Driven wheel 3 Wheel cover bracket 4 Saw beam 5 Guide section 6 Lathe bed

7 Driving wheel 8 Belt wheel 9 Surrounding edge 10 Base 11 Liquid level and temperature gauge

12 Tank cleaning cover 13 Side-mount oil filler

1 Guiding device

The left and right guide arms installed on the beam move along the dovetail groove and adjust the spacing between the guide arms and the workpiece 079-197in The guide device is used to change the angle relative to the lathe bed which the saw blade perpendicular to the bed surface the left and right guide heads are provided with a set of guide wheels and wear resistant alloy guide blocks 2 Tensioning device

The tensioning device consists of a tensioning seat a tensioning slider a screw rod etc when a saw

4

（ ）

blade is tensed saw blade can be tightened by using the hand wheel to rotate the screw rod clockwise If the sawing machine blocks for a long time turn the hand wheel counterclockwise to loosen the saw blade or replace the saw blade 3 Feed motion of saw blade

The hydraulic circulation system consists of lifting cylinder and throttle valve which controls the descending speed of saw beams to control the feed (stepless speed regulation) of the saw blade 4 Rotation of copper wire brush

Rotate along the direction of the saw at the place where the saw blade is sheared and clean by water pump cooling fluid to remove the sawdust on the saw blade V Driving system 1 Rolling Bearing Location Drawing Schematic Diagram of Guide Head Bearing Structure Schematic Diagram of Angular Bearing

Schematic Diagram of Driven Wheel Bearing

1 Bearing of driven wheel 2Lock nut retaining washer 3Gland of driven wheel

4Spacer bushing

5 Driven wheel 6Tensioning wheel 7Tensioning socket 8Tensioning slider 9Revolver gasket

10 Tensioning seat clamp plate 11Hollow bolt

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

1

1

I Main application

Apart from the functions of vertical sawing the whole saw frame rotating band sawing machine can implement material clockwise 0~45degof oblique cutting the fixed jaw and the material does not need to change for the sake of saving space It is applicable to channel steel H steel and other heterosexual steel as well as plate and metal materials II Main technical parameters

1 Main specifications

Main Technical Parameters Table I

III Machine tool lifting and installation

1 Lifting

When transporting the machine tools use the lifting equipment to the greatest extent The connection method of the steel cable during lifting is shown in Figure 1 Soft objects such as wood blocks and rubber should be placed where the steel cable may touch the parts whereby avoiding the damage to the parts and the paint 2 Unpacking

The Packing List should be checked for the quantity of the goods when unpacking 3 Installation

The machine tools should be installed in the where is free of obvious seismic source and the foundation of concrete structure can be adopted the ground should be flat there should be enough space around the machine easy to install debug maintain and convenient for other operations etc The level gauge is placed on the middle bed surface of the clamping port and the machine tool mat (purchased by the customer) or pad iron with sawing machine cabinet base shall be adjusted respectively along the longitudinal and transverse direction Tighten the anchor bolts when the sawing machine is in horizontal level refer to figure 2

Type of sawing machine GB4035H

Range of saw cutting (in)90deg Φ13 322520 1532 x 11 13245deg Φ11 131611 1316 x 9 2664

Specification of saw blade length x width x thick 185 364 x 1 1132 x 364Cutting speed 905 33641535 7162519

11163307 332Feed speed inmin Stepless speed controlPower of main motor K W 22KWMotor power of oil pump KW 1120Water pump power KW 125Physical dimension (length X width X height ) of the machine tool 98 2764 x 59 116 x 55 18

2

Figure 1 Hoisting Drawing of Machine Tool

Figure 2 Schematic Diagram of Horizontal

Adjustment of Machine Tool

Figure 3 Schematic Diagram of

Foot Margin

IV Main structure

Anchor Bolt

A-A

3

The inner cavity of the base has large space the front side is the hydraulic oil tank the back side is the hydraulic system and the right side is the coolant tank Lathe bed bearing seat fixed on the base and lathe bed can rotate 0~45deg and the bed body is equipped with jaw clamping screw and slide block the left with the clamping cylinder and the hand wheel The tightening and loosening the work-piece can be achieved by rotary valve when the screw rod turns the left clamp port away from the work-piece 039-098in The back side is equipped with a feeding mechanism the front side is equipped with a feeding plate the saw beam rotates around a supporting shaft the left side of the saw beam is equipped with a tension seat a driven wheel and the right side with a worm gear case The motor behind the worm gear case drives the driving wheels to rotate and then drives the saw blade around the active and driven wheels for cutting motion and the cutting accuracy is adjusted by the middle guide arm and the guide head The motions of sawing machine is controlled by hydraulic and electric system

Figure 4 Drawing of Machine Tool Structure

1 Electrical box 2 Driven wheel 3 Wheel cover bracket 4 Saw beam 5 Guide section 6 Lathe bed

7 Driving wheel 8 Belt wheel 9 Surrounding edge 10 Base 11 Liquid level and temperature gauge

12 Tank cleaning cover 13 Side-mount oil filler

1 Guiding device

The left and right guide arms installed on the beam move along the dovetail groove and adjust the spacing between the guide arms and the workpiece 079-197in The guide device is used to change the angle relative to the lathe bed which the saw blade perpendicular to the bed surface the left and right guide heads are provided with a set of guide wheels and wear resistant alloy guide blocks 2 Tensioning device

The tensioning device consists of a tensioning seat a tensioning slider a screw rod etc when a saw

4

（ ）

blade is tensed saw blade can be tightened by using the hand wheel to rotate the screw rod clockwise If the sawing machine blocks for a long time turn the hand wheel counterclockwise to loosen the saw blade or replace the saw blade 3 Feed motion of saw blade

The hydraulic circulation system consists of lifting cylinder and throttle valve which controls the descending speed of saw beams to control the feed (stepless speed regulation) of the saw blade 4 Rotation of copper wire brush

Rotate along the direction of the saw at the place where the saw blade is sheared and clean by water pump cooling fluid to remove the sawdust on the saw blade V Driving system 1 Rolling Bearing Location Drawing Schematic Diagram of Guide Head Bearing Structure Schematic Diagram of Angular Bearing

Schematic Diagram of Driven Wheel Bearing

1 Bearing of driven wheel 2Lock nut retaining washer 3Gland of driven wheel

4Spacer bushing

5 Driven wheel 6Tensioning wheel 7Tensioning socket 8Tensioning slider 9Revolver gasket

10 Tensioning seat clamp plate 11Hollow bolt

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

1

I Main application

Apart from the functions of vertical sawing the whole saw frame rotating band sawing machine can implement material clockwise 0~45degof oblique cutting the fixed jaw and the material does not need to change for the sake of saving space It is applicable to channel steel H steel and other heterosexual steel as well as plate and metal materials II Main technical parameters

1 Main specifications

Main Technical Parameters Table I

III Machine tool lifting and installation

1 Lifting

When transporting the machine tools use the lifting equipment to the greatest extent The connection method of the steel cable during lifting is shown in Figure 1 Soft objects such as wood blocks and rubber should be placed where the steel cable may touch the parts whereby avoiding the damage to the parts and the paint 2 Unpacking

The Packing List should be checked for the quantity of the goods when unpacking 3 Installation

The machine tools should be installed in the where is free of obvious seismic source and the foundation of concrete structure can be adopted the ground should be flat there should be enough space around the machine easy to install debug maintain and convenient for other operations etc The level gauge is placed on the middle bed surface of the clamping port and the machine tool mat (purchased by the customer) or pad iron with sawing machine cabinet base shall be adjusted respectively along the longitudinal and transverse direction Tighten the anchor bolts when the sawing machine is in horizontal level refer to figure 2

Type of sawing machine GB4035H

Range of saw cutting (in)90deg Φ13 322520 1532 x 11 13245deg Φ11 131611 1316 x 9 2664

Specification of saw blade length x width x thick 185 364 x 1 1132 x 364Cutting speed 905 33641535 7162519

11163307 332Feed speed inmin Stepless speed controlPower of main motor K W 22KWMotor power of oil pump KW 1120Water pump power KW 125Physical dimension (length X width X height ) of the machine tool 98 2764 x 59 116 x 55 18

2

Figure 1 Hoisting Drawing of Machine Tool

Figure 2 Schematic Diagram of Horizontal

Adjustment of Machine Tool

Figure 3 Schematic Diagram of

Foot Margin

IV Main structure

Anchor Bolt

A-A

3

The inner cavity of the base has large space the front side is the hydraulic oil tank the back side is the hydraulic system and the right side is the coolant tank Lathe bed bearing seat fixed on the base and lathe bed can rotate 0~45deg and the bed body is equipped with jaw clamping screw and slide block the left with the clamping cylinder and the hand wheel The tightening and loosening the work-piece can be achieved by rotary valve when the screw rod turns the left clamp port away from the work-piece 039-098in The back side is equipped with a feeding mechanism the front side is equipped with a feeding plate the saw beam rotates around a supporting shaft the left side of the saw beam is equipped with a tension seat a driven wheel and the right side with a worm gear case The motor behind the worm gear case drives the driving wheels to rotate and then drives the saw blade around the active and driven wheels for cutting motion and the cutting accuracy is adjusted by the middle guide arm and the guide head The motions of sawing machine is controlled by hydraulic and electric system

Figure 4 Drawing of Machine Tool Structure

1 Electrical box 2 Driven wheel 3 Wheel cover bracket 4 Saw beam 5 Guide section 6 Lathe bed

7 Driving wheel 8 Belt wheel 9 Surrounding edge 10 Base 11 Liquid level and temperature gauge

12 Tank cleaning cover 13 Side-mount oil filler

1 Guiding device

The left and right guide arms installed on the beam move along the dovetail groove and adjust the spacing between the guide arms and the workpiece 079-197in The guide device is used to change the angle relative to the lathe bed which the saw blade perpendicular to the bed surface the left and right guide heads are provided with a set of guide wheels and wear resistant alloy guide blocks 2 Tensioning device

The tensioning device consists of a tensioning seat a tensioning slider a screw rod etc when a saw

4

（ ）

blade is tensed saw blade can be tightened by using the hand wheel to rotate the screw rod clockwise If the sawing machine blocks for a long time turn the hand wheel counterclockwise to loosen the saw blade or replace the saw blade 3 Feed motion of saw blade

The hydraulic circulation system consists of lifting cylinder and throttle valve which controls the descending speed of saw beams to control the feed (stepless speed regulation) of the saw blade 4 Rotation of copper wire brush

Rotate along the direction of the saw at the place where the saw blade is sheared and clean by water pump cooling fluid to remove the sawdust on the saw blade V Driving system 1 Rolling Bearing Location Drawing Schematic Diagram of Guide Head Bearing Structure Schematic Diagram of Angular Bearing

Schematic Diagram of Driven Wheel Bearing

1 Bearing of driven wheel 2Lock nut retaining washer 3Gland of driven wheel

4Spacer bushing

5 Driven wheel 6Tensioning wheel 7Tensioning socket 8Tensioning slider 9Revolver gasket

10 Tensioning seat clamp plate 11Hollow bolt

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

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2525

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1616

Oi lOi l pumppump runrun

34343333

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Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

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SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

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7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

2

Figure 1 Hoisting Drawing of Machine Tool

Figure 2 Schematic Diagram of Horizontal

Adjustment of Machine Tool

Figure 3 Schematic Diagram of

Foot Margin

IV Main structure

Anchor Bolt

A-A

3

The inner cavity of the base has large space the front side is the hydraulic oil tank the back side is the hydraulic system and the right side is the coolant tank Lathe bed bearing seat fixed on the base and lathe bed can rotate 0~45deg and the bed body is equipped with jaw clamping screw and slide block the left with the clamping cylinder and the hand wheel The tightening and loosening the work-piece can be achieved by rotary valve when the screw rod turns the left clamp port away from the work-piece 039-098in The back side is equipped with a feeding mechanism the front side is equipped with a feeding plate the saw beam rotates around a supporting shaft the left side of the saw beam is equipped with a tension seat a driven wheel and the right side with a worm gear case The motor behind the worm gear case drives the driving wheels to rotate and then drives the saw blade around the active and driven wheels for cutting motion and the cutting accuracy is adjusted by the middle guide arm and the guide head The motions of sawing machine is controlled by hydraulic and electric system

Figure 4 Drawing of Machine Tool Structure

1 Electrical box 2 Driven wheel 3 Wheel cover bracket 4 Saw beam 5 Guide section 6 Lathe bed

7 Driving wheel 8 Belt wheel 9 Surrounding edge 10 Base 11 Liquid level and temperature gauge

12 Tank cleaning cover 13 Side-mount oil filler

1 Guiding device

The left and right guide arms installed on the beam move along the dovetail groove and adjust the spacing between the guide arms and the workpiece 079-197in The guide device is used to change the angle relative to the lathe bed which the saw blade perpendicular to the bed surface the left and right guide heads are provided with a set of guide wheels and wear resistant alloy guide blocks 2 Tensioning device

The tensioning device consists of a tensioning seat a tensioning slider a screw rod etc when a saw

4

（ ）

blade is tensed saw blade can be tightened by using the hand wheel to rotate the screw rod clockwise If the sawing machine blocks for a long time turn the hand wheel counterclockwise to loosen the saw blade or replace the saw blade 3 Feed motion of saw blade

The hydraulic circulation system consists of lifting cylinder and throttle valve which controls the descending speed of saw beams to control the feed (stepless speed regulation) of the saw blade 4 Rotation of copper wire brush

Rotate along the direction of the saw at the place where the saw blade is sheared and clean by water pump cooling fluid to remove the sawdust on the saw blade V Driving system 1 Rolling Bearing Location Drawing Schematic Diagram of Guide Head Bearing Structure Schematic Diagram of Angular Bearing

Schematic Diagram of Driven Wheel Bearing

1 Bearing of driven wheel 2Lock nut retaining washer 3Gland of driven wheel

4Spacer bushing

5 Driven wheel 6Tensioning wheel 7Tensioning socket 8Tensioning slider 9Revolver gasket

10 Tensioning seat clamp plate 11Hollow bolt

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

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7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

3

The inner cavity of the base has large space the front side is the hydraulic oil tank the back side is the hydraulic system and the right side is the coolant tank Lathe bed bearing seat fixed on the base and lathe bed can rotate 0~45deg and the bed body is equipped with jaw clamping screw and slide block the left with the clamping cylinder and the hand wheel The tightening and loosening the work-piece can be achieved by rotary valve when the screw rod turns the left clamp port away from the work-piece 039-098in The back side is equipped with a feeding mechanism the front side is equipped with a feeding plate the saw beam rotates around a supporting shaft the left side of the saw beam is equipped with a tension seat a driven wheel and the right side with a worm gear case The motor behind the worm gear case drives the driving wheels to rotate and then drives the saw blade around the active and driven wheels for cutting motion and the cutting accuracy is adjusted by the middle guide arm and the guide head The motions of sawing machine is controlled by hydraulic and electric system

Figure 4 Drawing of Machine Tool Structure

1 Electrical box 2 Driven wheel 3 Wheel cover bracket 4 Saw beam 5 Guide section 6 Lathe bed

7 Driving wheel 8 Belt wheel 9 Surrounding edge 10 Base 11 Liquid level and temperature gauge

12 Tank cleaning cover 13 Side-mount oil filler

1 Guiding device

The left and right guide arms installed on the beam move along the dovetail groove and adjust the spacing between the guide arms and the workpiece 079-197in The guide device is used to change the angle relative to the lathe bed which the saw blade perpendicular to the bed surface the left and right guide heads are provided with a set of guide wheels and wear resistant alloy guide blocks 2 Tensioning device

The tensioning device consists of a tensioning seat a tensioning slider a screw rod etc when a saw

4

（ ）

blade is tensed saw blade can be tightened by using the hand wheel to rotate the screw rod clockwise If the sawing machine blocks for a long time turn the hand wheel counterclockwise to loosen the saw blade or replace the saw blade 3 Feed motion of saw blade

The hydraulic circulation system consists of lifting cylinder and throttle valve which controls the descending speed of saw beams to control the feed (stepless speed regulation) of the saw blade 4 Rotation of copper wire brush

Rotate along the direction of the saw at the place where the saw blade is sheared and clean by water pump cooling fluid to remove the sawdust on the saw blade V Driving system 1 Rolling Bearing Location Drawing Schematic Diagram of Guide Head Bearing Structure Schematic Diagram of Angular Bearing

Schematic Diagram of Driven Wheel Bearing

1 Bearing of driven wheel 2Lock nut retaining washer 3Gland of driven wheel

4Spacer bushing

5 Driven wheel 6Tensioning wheel 7Tensioning socket 8Tensioning slider 9Revolver gasket

10 Tensioning seat clamp plate 11Hollow bolt

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

4

（ ）

blade is tensed saw blade can be tightened by using the hand wheel to rotate the screw rod clockwise If the sawing machine blocks for a long time turn the hand wheel counterclockwise to loosen the saw blade or replace the saw blade 3 Feed motion of saw blade

The hydraulic circulation system consists of lifting cylinder and throttle valve which controls the descending speed of saw beams to control the feed (stepless speed regulation) of the saw blade 4 Rotation of copper wire brush

Rotate along the direction of the saw at the place where the saw blade is sheared and clean by water pump cooling fluid to remove the sawdust on the saw blade V Driving system 1 Rolling Bearing Location Drawing Schematic Diagram of Guide Head Bearing Structure Schematic Diagram of Angular Bearing

Schematic Diagram of Driven Wheel Bearing

1 Bearing of driven wheel 2Lock nut retaining washer 3Gland of driven wheel

4Spacer bushing

5 Driven wheel 6Tensioning wheel 7Tensioning socket 8Tensioning slider 9Revolver gasket

10 Tensioning seat clamp plate 11Hollow bolt

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

5

（ ）

（ ）

Schematic Diagram of Turbine Box Bearing Schematic Diagram of Fixed Pedestal BearingSupporting axle

Schematic Diagram of Turntable Bearing Schematic Diagram of Supporting Pedestal Bearing

1 Wheel centering 2Wheel nut 3Turntable 1Axial sleeve 2Supporting axle

3Worm gear case body 4Bearing seat

Rolling Bearing Schedule IIVI Hydraulic transmission system This hydraulic circuit composed of oil pump motor gear pump valve oil cylinder oil tank pipeline and

other components achieves saw beam lifting under electrical control clamping and loosening of workpiece

and other motion requirements Stepless speed regulation of feed rate can be realized through throttling

valve whereby achieving different materials of the workpiece with different feeding speed saw cutting

needs See the Drawing 5

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

6

Drawing 5 Hydraulic Schematic Diagram

SN Bearing Model Specification mm Quantity Installation position

1 Deep groove ball bearing 6201 12X32X10 4 Guide head

2 Tapered roller bearing 30208 40X80X2475 2 Driven wheel

3 One-way flat-bottom thrust

sphere bearing

51204 20X40X14 1 Tension screw

4 Tapered roller bearing 30207 35X72X15 2 Worm

5 Deep groove ball bearing 6306 30X72X19 1 Worm

6 Deep groove ball bearing 6200 10X30X9 4 Guide head

7 One-way flat-bottom thrust

sphere bearing

51116 80x105x19 1 Turntable

8 One-way flat-bottom thrust

sphere bearing

51110 50X70X14 2 Bearing seat

9 Deep groove ball bearing 6004 20X42X12 2 Angle transposition

10 Deep groove ball bearing 6204 20X47X14 1 Fixed base

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

7

Sequence Table of Electromagnetic Actions III

1 Press the stop button to control the power

dump and stop all the works Turn slightly clockwise to switch on the control power

2 Work Press the work button solenoid valve (3) 3YV to work the lifting oil cylinder without rod chamber

hydraulic oil passes through T hole from B hole the solenoid valve (4) 5YV works and then returns to the

oil tank through the throttle valve (5) Controlling the saws beam to drop (clockwise rotation speeds up

counterclockwise rotation slow down speed stop descending finally) through the throttle valve stepless

speed regulation The saw blade is operated and cut Then the saw blade stops running and the saw beam

rises automatically when the workpiece is cut and the lower limit switch is reached

3 Fast falling of saw beam When the saw blade is too high from the workpiece spatially press the down

button to make solenoid valve (3) 3YV start working the lifting oil cylinder without the rod cavity hydraulic

oil passes through T hole from B hole then it runs through the solenoid valve (4) and back to the oil tank

from P hole through B hole the saw beam shall rapidly descend to about 20-50mm from the workpiece as

yet

4 Ascending of saw beam Press the ascending button the solenoid valve (3) 4YV starts to work and the

hydraulic oil enters the lug chamber of the lifting cylinder through hole A and then the hole P Hydraulic oil

with the rod cavity returns to the oil tank

5 Workpiece clamping Press the clamping button solenoid valve (3) 2YV to start the work hydraulic oil

runs through the hole A to enter left cavity of clamping cylinder and the hydraulic oil of right cavity runs

through the hole B sump tank to realize the workpiece clamping

6 Workpiece loosening Press the clamping button solenoid valve (3) 1YV to start the work hydraulic oil

enters the right chamber of the cylinder through hole B and the left chamber through hole A and then runs

through the sump tank to realize the workpiece clamping

Cycle of operation 1YV 2YV 3YV 4YV 5YV

Rising +

Falling

Fast falling +

Workpiece falling + +

Clamping +

Loosening by clamp +

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

8

Hydraulic Component List IV

Notes Reducing system pressure when adjusting overflow valve clockwise Counterclockwise adjustment could increase system pressure The role of the overflow valve is to regulate system pressure automatic oil return is achieved when the pressure value exceeds the system pressure

VII Electrical control system 1 Electrical control system

The electrical control system consists of the control circuit of electrical cabinet control box junction box limit switch electromagnet etc which is used to control the rotation of saw blade as well as the lifting of saw beam the clamping of workpiece etc Press it to allow a certain program to conduct the cutting cycle When the power switch QS turns on control transformer works 36V control power is switched on and HL1 light will illuminate

A Press the SB1 to stop button to control power cut Stop all works and turn the SB1 stop button clockwise to switch on the control power

B Press the SB2 working button the KM1 coil is energized the host M1 and the pump M2 are activated and operated The normal and continuous operation of M1 and M2 must be under the condition of clamping press the clamping button SB5 KM4 coil will be energized and KM4 self-locking contact will then be clamped Upon clamping of KM1 through the parallel self-locking of KM1 and KM4 normally open contacts M1 and M2 are in continuous operation during the operation the saws are driven into motion And the 2YV downward solenoid valve is connected and the saw beam will then cut into through the constant open contact of KM1 When the sawing is in positon reaching lower limit switch then SQ1 SQ1 normally open contact closes when KM3 is energized the normally closed contact switches off KM1 disconnects and releases works of M1 and M2 then stop Saw cutting feed will stop then saw beam ascends automatically KM1 disconnects works of M1 and M2 will then stop

2 Protection equipment

1) In the control circuit we must start the oil pump motor first so that ascending control can be realized s o

SN Designation Specifications Quantity

1 Strainer HY37-25 1

2 Variable displacement vane

pump

VA1-15F-A2 1

3 Three-position four-way

solenoid valve4WE6E60AG24NZ5L 2

4 Two-position two-way

solenoid vale3WE6A50AG24NZ5L 1

5 One-way speed regulating

valve

FKC-G02 1

6 Clamping cylinder YGS354X197in 1

7 Lifting cylinder YGS315X1024in 1

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

9

will clamp control work Contactless for hoisting KM3 assists normally closed contacts to connect in series to the main engine contactor KM1 coil which make the host stop working when ascending Clamping contactor KM4 assists the normally opened contacts to connect in series to the host contactor KM1 self-locking circuit when clamping the work-piece the host can work continuously plus the host can work constantly the host will work by inching operation when workpieces are not clamped tightly

2) When the motor is overloaded the corresponding thermal relays of FR1 and FR2 of motor overload

protection will become overheat and drop out and cut off the corresponding circuit until then the machine

will stop working

List of Main

Electrical Components V

SN Code Designation Specifications Quantity

1 QS Power switch HZ5-20S4 1

2 QF1 Fuse base NXB-63Z C32 1

3 QF Fuse wire NXB-63Z C6 3

4 KM AC contactor CJX1-1222 4

5 FR1 Thermal relay JR36-20(68~11A) 1

6 FR2 Thermal relay JR36-20(32~5A) 1

7 VD Bridge rectifier block KBPC25-10 1

8 SQ Position switch YBLX19001 6

9 HL1 Signal light XDJ2-A36V 1

10 HL2 Working light 40W 36V 1

11 SB1 Emergency stop button LAY16CR01 1

12 SB2 Ordinary button LAY16AW11 4

13 SB3 Ordinary button LAY16AW10 3

14 SB4 Ordinary button LAY16AW22 1

15 TC Control transformer BK-150VA230V36v27v 1

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

10

Figure 6 Machine Control Schematic Diagram

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

11

M1

M2

M3

3~

3~

3~

QS

KM2

KM1

FR1

FR2

U V WW

U230V

60Hz

QF3

QF4

QF2

SB1

EL

KM3

SQ2

SQ1

KM4

KM4

KM3

KM3 2YV

3YV

4YV

5YV

KM1

KM3

FR2

FR1

KM1

KM2

KM3

KM4

SB2

Cooling

motor

Main

motor

Hydraulic

motor

SB3

SB7

SB1

SB6

SB9

SB9

SB8

SB3

PE

DB-12A

40W

HL

U1

V1

W1

W2

V2

U2

QF1

BK-150VA

VC

68-11A

32-5A

KM4

KM1

22Kw

960rmin

075kw

1400rmin

1YV

SB7

KM1

Power

switoh

UP

Fasten

Release

Down

Running

oil

pump

run

Fasten

Up

Fuse

gear

Main

frame

cooling

pump

Oil

pump

Control

transformer

Mainframe

norking

L3

L2

L1

230V

36V

27V

24V

SB4

SB5

KM2

SQ3

SQ4

SQ5

SQ6

SB1Emergency

stop

SB2stop

SB3Running

SB4Oil

pump

stop

SB5Oil

pump

run

SB6Up

SB7Down

SB8Fasten

SB9Release

Saw machine control diagram figure

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

WVU

PEPE

230V230V 60HZ60HZ

PEPE

PEPE

PEPE

LL

212122220127V27V

2626252524242323 W2W2V2V2U2U2

1

2

Di r eetDi r eet cur r entcur r ent outout 24V24V

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

2222

3030

2020

2828

KM3KM3 KM2KM2 KM4KM4Mai nMai n mot ormot orOi lOi l pumppump mot ormot orRi s eRi s e andand f al lf al l

CJx1- 1222CJx1- 1222CJx1- 12 22CJx1- 12 22CJx1- 12 22CJx1- 12 22

QSQS

QF1QF136V36V

075KW075KW

OilOil pumppumpmotormotor

BK-150VABK-150VA

FastenFasten

UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

Si gnalSi gnal l i ghtl i ght

SQ2SQ2

SQ1SQ1

LowestLowest limitlimit switchswitch

10109

HighestHighest limitlimit switchswitch11111010

WorkingWorking lightlight40W40W36V36V

02

3030

2727

3030

2323

3030

2424

32

20

W2W2V2V2U2U2W1W1V1V1U1U13030232324242727282820

L1L1 L2L2 L3L3

000

728282929982828

2828

2323

2727

1010 1010

1111

2828

4

9

1111

2424

WVUWVU

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

U2U2 V2V2 W2W2 U1U1 V1V1 W1W1

3 4 1010 1111

5A5A 11A11AW2W2V2V2U2U2 U1U1 V1V1 W1W1

QF1QF1

U V W

C32C32

6A6A

3 4 10109 1111

RunningRunning

StopStop

73

7

5

8

7

UpUp

10109

DownDown27272828

9524242828

2626 2525

2525

3030

2626

3030

FastenFasten ReleaseRelease

1414

OpenOpen thethe dooranddoorand powerpower offoff

FastenFasten

16161515

ReleaseRelease

2828

1515

2626

3

L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1

PowerPower l i nel i ne Oi lOi l pumppump Mai nMai n mot ormot or Cool i ngCool i ng mot ormot or

2121

2222

QF3QF3 6A6AKM4KM4ClampClamp l oosenl oosen

CJx1- 1210CJx1- 1210

0

15158

2828

9

2525

1616

1616

Oi lOi l pumppump runrun

34343333

Oi lOi l pumppump s tops top

33332

3333 3434

3333

3434

0101

1

0101

QF2QF2 6A6A

Al t er nati ngAl t er nati ng cur r entcur r ent i nputi nput 27V27V

Di r eetDi r eet cur r entcur r ent outout 24V24V

SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6

SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

12

Note I fNote I f t echi ni calt echi ni cal datedate subj ectsubj ect toto change ref erchange ref er toto thethe real i t yreal i t y

230V230V 60HZ60HZ

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UpUpDownDownThrottleThrottle

Emer gencyEmer gency s tops top

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LowestLowest limitlimit switchswitch

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HighestHighest limitlimit switchswitch11111010

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SecuritySecurity

77777 1212 1313

0 36Vnul l0 36Vnul l lineline 01 work01 work lightlight2 Si gnal2 Si gnal lamplamp 33 oi l33 oi l pumppumpl ocki ngl ocki ng34 oi l34 oi l pumppumpworki ngworki ng 3run3run thethe locklock4 mai n4 mai n motormotor runni ngrunni ng 7- 77 des i gh7- 77 des i gh schemescheme9 down9 down limitlimit 10 ri si ng10 ri si ng l ocki ngl ocki ng 11 ri si ng11 ri si nglimitlimit12 f ast en12 f asten 13 rel ease13 rel ease 28 24Vcont r ol28 24Vcont r ol busbus27 DCf astdrop27 DCf astdrop 26 DCrel ease26 DCrel ease 25 DCf asten25 DCf asten24 DCdown24 DCdown 23 DCri se23 DCri se 30 DCnul l30 DCnul l lineline

7

7777

Electrical device of saw machine

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

13

VIII Lubrication and cooling system 1 Lubrication system 1) Carry out oil filling in strict accordance with the requirements of Table VI and the Figure 8 Diagram of

Lubrication Position of Machine Tool before starting 2) Lubrication of worm gear case No 30 engine oil bath is used to lubricate the worm gear case The oil

content in the box is about 1 kg The oil plug hole on the upper part of the worm gear case is injected and there is oil mark on the side of the box body The oil surface should be above the oil mark and between the lower limit when the saw beam is at the lowest position Oil should be replaced after a month of grinding afterwards oil shall be changed every 3-6 months for each shift The lower part of the worm gear case is provided with oil drain bolts Hydraulic oil and coolant drain plug are set at the bottom of the machine box

Figure 8 Diagram of Lubrication Position of Machine Tool

Lubrication Area Chart VI

SN Lubrication parts Grease varieties Lubrication interval Lubrication

method

1 Brush shaft for copper wire Engine oil Once per shift Oil can

2 Driving wheel bearing Butter Once per shift Oil gun

3 Worm bearing Butter Once per shift Oil gun

4 up and down shaft of lift cylinder Engine oil Once per shift Oil can

5 Bearing of driven wheel Butter Once per shift Oil gun

6 Tensioning device guide rail

tensioning screw plane bearing

Butter mobile oil Once per shift Oil can oil

gun

7 Guide head rolling bearing Engine oil Once per shift Oil can

8 Slide surface of the left jaw Engine oil Once per shift Oil can

9 Elevator shaft of saw beam Engine oil Once per shift Oil can

10 Surface bearing Butter Once per shift Oil gun

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

14

2 Cooling system

The cooling fluid passes through the water pump and plastic hose to the three-way pipe installed on the saw beam and rinses scrap irons all the way to the copper brush Another way to install in the guide arm aluminum water gun so that the saw blade cutting area is well cooled and lubricated refer to Figure 9

The role of cooling fluid is cooling and lubricating and high-performance cooling fluid shall be added during operation for the sake of improving the life of the saw blade cutting efficiency and ensuring the processing quality Use clean water added in the prescribed proportion to conduct dilution The method refers to firstly inject the cooling liquid into the pool and then pour the water into the pool gradually and stir the water while filling until the liquid level is 394-472in higher than that of the tank bottom

The working concentration of cutting fluid is usually 5 that is the ratio of cutting fluid to water is 120 which will naturally decrease in the use process and should be added according to the working concentration The concentration should be increased to about 10 when cutting difficult materials

Figure 9 Cooling System Diagram

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

15

IX Operating system 1 Refer to Figure 10 for Operating System Panel Diagram

Figure 10 Operating System Panel Diagram

STEPLESS SPEED CONTROLEMERGENCY STOP

SI GNAL LI GHT OI L PUMP RUN

OI L PUMP STOP

RUNNI NG

STOP DOWN

UPFASTEN

RELEASE0

5

10Do Not Hi t Panel Ar ea

2 Composition and function of control panel

Close the power switch light the power signal lamp and connect the power of sawing machine

1 Press the stop button cut off the control power supply rotate clockwise If the mushroom handle rises

outward the control power is connected If pushing inwards the mushroom handle compresses inwards

and the control power is disconnected

2 Press the work button operate the main motor with saw blade operate the water pump to achieve the

cooling cycle Inching control can be started if not pressing clamp button The main motor and water

pump will stop running when pressing stop button

3 When pressing the up button the main engine stops running the saw beam goes up When contacting

the upper limit switch the rising stops The saw beam goes down when pressing down button

4 When rotating stepless speed control button clockwise the feed speed of saw blade accelerates When

rotating anticlockwise it slows down and finally stops

5When one of the safety shields is not closed and the saw blade is broken the machine will be powered off

and cannot be started

3 Other control mechanisms

Regulate the lock nut on the locating rod with the workpiece length control block to determine the relative position of one end of workpiece to the cut edge of saw blade

X Regulation of Machine Tool 1 Place the machine tool on the flat ground without vibration check whether the machine tool is intact and

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

16

clean the rust-proof oil on the machine tool

2 As shown in Figure 4 introduce the three-phase and four-wire from external power to the wiring board of

electrical box open the shutter of hydraulic oil add 46 hydraulic oil to the upper end of strainer

Power on to light the power indictor Clockwise rotate the emergency stop button and control the

connection of power control Press the work button of oil pump to operate the hydraulic system

3 Installation of saw blade

1) Spread the new saw blade and be careful not to touch the gears

2) Press up button to adjust the width of guide arm The width should be 118-197in wider than that of the

workpiece

3) Open the driving and driven wheel cover

4) Loosen the lock nut of the copper wire brush and lower it

5) Mount the saw blade on driving and driven wheel and be careful that the sawtooth is downward

6) Insert the saw blade into the place between the left and right guide head alloy block contact the saw back with the top alloy block

7) Make the back of saw blade close to the edge of driving and driven wheel and guarantee the spacing with the wheel edge of 004-007in Refer to Figure 13

8) Check the perpendicularity of the fixed clamping of the working vice against the side of the saw blade with a right-angle ruler The allowable error is 00079787in

9) To adjust the tension of the saw blade it must properly tighten the saw blade to ensure the normal sawing If the tension is overlarge the band saw blade is easy to break If the tension is too small it is easy to slide and lead to gear collision The tension is determined according to the materials and cutting size of cut workpiece which is generally 25-35Nm The above project should be completed in 2-3 times Do not tighten at once lest the force of the saw blade uneven (Note the saw blade should be loosened when off work to avoid premature fatigue of the saw blade)

10) Tighten the left and right adjustment bolts so that the alloy block compacts the saw blade

11) Adjust the position of copper wire brush to make it contact with the sawtooth The accurate position of copper wire brush and sawtooth is shown in Figure 11 The copper wire brush should be regulated at any time after the wear Finally the bolt should be tightened

Figure 11

(12) Adjust the deflection angle of driven wheel The plane of the moving direction from the axis line of the

driven wheel and the saw blade is not perpendicular In the case of not tightening the saw blade it is required

that the axis line of the driven wheel be inclined to the left 05deg-08deg perpendicular to the direction of the

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

17

blade motion as shown in Fig 11 The effect of the deflection angle is that the blade does not move down

along the outer edge of the driven wheel while the blade is running but the saw blades may be dropped The

deflection angle of driven wheel should be adjusted if the saw blade is dropped from the driven wheel The

adjustment method is as following

First according to the end plane of the driving wheel the first two screws on the tightening seat after

adjusting the driven wheel saw beam are shown in Figure 12 Adjust the parallelism between the driven

wheel and driving wheel (Inspection method Two pieces of Triple board with 35cm x 35 cm are placed on

the ends of the two saw wheels to see the edges of the two planks parallel) and then adjust the next bolt as

shown in Figure 11 Adjust the deflection angle (Adjust to the back of the saw blade with 1-2 mm free of the

end edge of the saw wheel) as shown

Figure 13 Tighten three more

adjustment screws to prevent loosening

Figure 12 Diagram of Adjustment of Deflection Angle

Figure 13 Reference Diagram of Local Gaps

Tensi on Bl ock

Bean Board

Dri ven Gear

Devi at i on Adj ustment Screw

Tensi on Bl ockHexagon Socket-head

Hol l ow Bol tBean Board

Dri ven Gear0 5-0 8deg

Cap Screws

Space of Bl ode Baokeand Sawi ng Wheel Pl ane1-2mm

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

18

(13) Cover the Drive Band wheel and Idler Band wheel

(14) The choice of saw blade speed

Saw blade speed is adjustable four grades 905 33641535 7162519 11163307 332

see the reference in Table 7 and 8 Chose suitable cutting speed according to the

material and nature of work piece In order to upgrade the saw blade life may choose

to use low 1-2 stalls cutting speed

5 transform saw blade speed

(1)Turn off the power switch open wheel cover

(2)Loosen locking nut of Motor Block

(3)Selected the cutting speed and exchange the location of texrope

(4)Tight locking nut of Motor Block

(5) Cover the Pulley

6 The cutting efficiency of easy cutting materials is usually cut hard materials

should be lower For example take the iron as describing if the iron in thin or

powder they should increase the cutting speed and if the iron is charred and thick

should lower the cutting speed The iron should be in roll with the correct cutting

speed see figure 16

7 The new Blade running-in

New saw blade must be carried out running-in before starting cutting Otherwise

they would shorten the life and become not effective cutting

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

19

XI Common Faults and Removal Solutions

XII Appendix table

Table 7 Reference Table of Cutting Rate of Saw Blade

SN Fault name Reasons Troubleshooting method1 Broken teeth of

saw blade1 Saw blade back blocks the rim Adjust the slide seat in the guide arm or tensioning

mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

2 The workpiece itself is irregular in shape

Adjust the slide seat in the guide arm or tensioning mechanism so that there is a slight gap between the blade back and the flange during the running of the saw blade

3 Sawing machine overload Reduce feed speed4 Saw blade not tight Tensioning saw blade5 Deposited chips in the guide block Remove guide block for cleaning6 Saw blade selection is not appropriate

Select the appropriate saw blade according to the material

7 Too slow of saw blade speed Speed up the operation8 Insufficient lubrication of coolant Increase the flow rate and adjust the lubricating

position9 Hydraulic oil is insufficient Add 46 hydraulic oil

2 1 The unstable feed is too slow and the adjustment range is small

Impurity blocks Valve pipeline 1 Remove and reinstall clean impurities2 Check the oil quality and replace it if necessary

2 Feed speed is too high

Speed regulating valve is discharged internally and the clamping force between valves is not enough

Clean speed regulating valve with diesel oil

3 Lifting cylinder leaks oil

Damage of seal ring Replace the sealing ring

3 Saw blade is dropped

1 The fixed guide surface of the two guide arms is not on the grandfather tangent of the two saw wheels

Adjust the guide arm

2 If the above method is invalid to adjust the position of the tensioning seat see figure 12

Adjust a screw to the left of the skateboard seat loosen it with a wrench and then tighten it clockwise against the edge of the saw blade

4 Poor cutting accuracy

1 The clamping face of saw blade and fixed vice is not perpendicular

Method as above

2 Saw blade wear Replace saw blade3 Feed speed is too high Reduce feed speed4 Guide arm loosening Fasten guide arm5 The distance between the two guide arms is too large

Reduce span

6 The guide bearing of guide arm is damaged

Replace the same type of bearing

7 Unfastened screws on guide arm Tighten with a wrench or handwheel

SN Fault name Reasons Troubleshooting method

5 Saw blade sliding

1 Feed speed is too high Reduce feed speed

2 Saw blade wear Replace saw blade

3 Workpiece loosening Correct clamping

4 Saw blade not tight Tensioning saw blade

6

High noise in

hydraulic system

1 Gas leakage of pipe joint Check the inlet and tighten the back of the seal ring at the joint

2 Pipe bending radius is too small Make adjustment

3 Oil pump and motor coupling are not concentric or loose Adjustment and Fastening

4 Low liquid level of oil tank Immerse the entire filter into the oil

7 Cutting vibration

1 Main drive wheel is unbalanced Conduct static balance

2 The base of the sawing machine is not firm Lock foot bolt

3 The guide arm of the saw blade is not fully locked Lock guide arm

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality

20

Sawing material Linear speed ftmin20-30 2755 293210-15 2755 293230-60 1771 2132

A5 2755 2932A3 2755 2932

CrMo 1771 2132cr 1771 2132

CrNiA 1771 2132crNiMoA 1771 2132

T4 1771 2132GCr 1771 2132

CrWMn 1771 2132W18cr4v 984 14

crNi 984 14crMoV 984 14

Noteif techinical date subject to changerefer to the reality