Blitzer 285 MG Manuel utilisateur

OPERATION MANUAL

Blitzer 285 MG Gravity Feed Mitre

Cutting Bandsaw 240v Single Phase

CONTENTS

1 SAFETY...................................................................7

1.1.SAFETY RULES ..............................................7

1.2.DANGER ZONE ON THE MACHINE............7

1.3.SAFETY EQUIPMENTS AND

ASSIGNMENTS .....................................................8

1.3.1.BREAK-OFF SWITCH .............................8

1.3.2.COVER SWITCH......................................8

1.3.3.DOWN LIMIT SWITCH ...........................8

1.3.4.EMERGENCY STOP BUTTON ...............8

1.4.WARNING LABEL AND ASSIGMENTS.......8

1.4.1.GLOVE LABEL........................................8

1.4.2.ELECTRICITY NEUTRAL WARNING

LABEL................................................................8

1.4.3.HIGH VOLTAGE LABEL ........................8

1.4.4.SAFETY EQUIPMENTS LABEL.............8

1.4.5.ARROW LABEL.......................................8

2 DESCRIPTION AND PROPERTIES...................9

2.1 TECHNICAL PROPERTIES OF THE

MACHINE ..............................................................9

2.2 STANDARD EQUIPMENT..............................9

2.3 NOISE LEVEL..................................................9

2.4 MACHINE DIMENSION .................................9

2.5 MACHINE CUTTING CAPACITY .................9

2.6 PROPERTIES TABLE ACCORDING TO

METAL SAWDUST...............................................9

3 TRASPORTATION AND INSTALLATION.....10

3.1.HANDLING THE UNPACKED MACHINE .10

3.2.AFTER UNPACKING THE MACHINE........10

3.3.ENVIRONMENTAL CONDITIONS .............10

3.4.MACHINE PLACEMENT AND POSITION.10

4 PREPARATION BEFORE OPERATION.........10

4.1.CLEANING.....................................................10

4.2.LUBRICATING..............................................10

4.3.COOLANT......................................................10

4.4.ELECTRICAL POWER CONNECTION .......10

4.5.FINAL INSPECTION CHECKLIST BEFORE

OPERATION.........................................................11

5 OPERATION........................................................ 11

5.1. CONTROL PANEL ....................................... 11

5.2. BLADE CHANGING PROCEDURE............ 11

6 MAINTENANCE.................................................. 13

6.1.DAILY MAINTENANCE .............................. 13

6.2.WEEKLY MAINTENANCE.......................... 13

6.3.MONTHLY MAINTENANCE....................... 13

6.4.SIX-MONTHLY MAINTENANCE ............... 13

6.5.PERIODIC MAINTENANCE ........................ 13

7 TROUBLESHOOTING ...................................... 14

8 DISMANTLING ................................................... 15

9 SPARE PART LIST ............................................. 16

9.1.MACHINE BASE ASSEMBLY..................... 17

9.1.1. MACHINE BASE UPPER FRAME ....... 18

9.2.FLANGE JOINT ASSEMBLY....................... 19

9.3.CLAMP ASSEMBLY..................................... 20

9.4.BOW ASSEMBLY ......................................... 21

9.5.GEARBOX ASSEMBLY ............................... 22

9.6.BLADE TENSIONING ASSEMBLY ............ 23

9.7.BOW LIFT CYLINDER ASSEMBLY........... 24

9.8.BLADE GUIDE ASSEMBLY........................ 25

9.9.MOBILE BLADE GUIDE COMPLETE ........ 25

9.10.FIXED BLADE GUIDE COMPLETE.......... 26

9.11.SPRING ASSEMBLY................................... 27

9.12.CLAMP COMPLETE ................................... 28

10 CONTROL CIRCUIT DIAGRAM................... 29

11 POWER CIRCUIT DIAGRAM........................ 30

1SAFETY

1.1 . Safety Rules

Never allow unqualified persons to

operate or interfere with the machine

It is important to develop personal safety

awareness. Observe all related safety

regulations and pay attention for

hazardous conditions. Discuss these

conditions with your supervisor.

You must use personal protective

equipment, like safety glasses, gloves,

safety work shoes.

Do not remove warning signs and/or

instruction plates off the machine.

Make sure that all machine controls are

set for the desired mode of operation,

whenever the setting of the machine

control is changed, run the machine in

slow mode to make sure it operates as

expected.

Never disable any safety device to avoid

its assigned function. These devices are

intended to protect both the machine and

its operator.

Do not load, unload, operate or adjust the

machine without proper instructions.

This machine is specifically designed for

cutting general metal material. Do not cut

wood and analogous material, meat,

fishery, food and agriculture products,

combustible and radioactive materials.

Enough space should be provided around

the machine to avoid hitting and provide a

convenient operation.

Do not leave any tool on the machine after

use. Do not put work stock or tools

around the machine, to avoid injury.

Do not operate the machine with its safety

guards removed.

Do not wear gloves when operating

through control panel.

Wear gloves only when

loading/unloading the material, changing

the blade and chip brush.

Never touch the blade, moving work stock,

nor put your hands into the vise area or

chip conveyor unit until the machine halts

completely.

When selecting blade, blade speed and

coolant, please refer to the operation

manual or related documents.

Before installation and operate the

machine check the sufficiency of the earth

of the machine to your electrician. Do not

operate the machine without the earth.

Determined and declared bench life of the

machine by the Ministry of Industry and

Trade is 10 years.

For longevity please follow the

maintenance directions at the manual.

1.2 . Danger Zones on the Machine

Do not open the guards/covers during

operation.

During cutting process keep your

hands and fingers away from running

blade which should on number one.

During cutting process keep away

from zone number two. It may cause

hitting and dropping injury.

Do not Touch electrical panel if you

are not expert on electric

1.3. Safety Equipments and Assignments

1.3.1. Break-off Switch

This switch is used for to stop the machine while

the blade pressure gets smaller than adjusted ones.

The main causes of decrease in pressure are;

dulling, cracking or breaking of blade. Operating

the machine under these conditions endanger the

operator.

1.3.2. Cover Switch

This switch provides to shut down the machine

while the bow cover is open. Running the

machine may cause wounding and serious gashes.

Machine gives aural warning while the cover is

open.

1.3.3. Down Limit Switch

This switch is used to adjust the bow’s nadir to

goes down. Down limit switch is a factory setting.

Please do not tinker with the down limit switch.

1.3.4. Emergency Stop Button

Emergency stop button, places on the operator

control panel- near the main switch, is red button

and you can see it easily. In emergency cases,

press to this button to stop the machine. Machine

does not run while the button is pressed. To rerun

the machine, please turn left and release the

button.

1.4. Warning Labels and Assigments

1.4.1. Glove Label

Please use personal protective

equipment, like glove, during

operation and while changing the

blade.

1.4.2. Electricity Neutral Warning Label

In this label, we

declared the

instructions how

to make the electric connection before installing

machine or after handling the machine.

1.4.3. High Voltage Label

This label shows high voltage risk

parts. All electrical connections

should be done by a qualified

electrician.

1.4.4. Safety Equipments Label

All the safety devices

and guards are

designed to intend to

protect the operator.

Please do not remove these safety guards.

1.4.5. Arrow Label

Blade’s direction of rotation

belongs to machine. Arrow label

on the machine shows blade’s

direction of rotation. Please pay

attention on direction of rotation

while changing blade.

Cover Switch

Break-off

Switch

Down Limit

Switch

2DESCRIPTION AND

PROPERTIES

2.1. Technical Properties of the Machine

MAIN MOTOR

1,1 kW, 1400 rpm

COOLANT PUMP

0,09 kW, 2800 rpm

CUTTING SPEED

25-90 m/min

BLADE DIMENSION

2500x27x0,9

BLADE TENSION

Min. 30 bar -Max. 50 bar

BLADE QUALITY

Bi Metal

HEIGHT OF VISE BED

915 mm

WEIGHT

260 Kg.

MACHINE DIMENSION

800 x1560 x 1500 mm

NUMBER OF PHASE

FREQUENCY

60 Hz

MAIN VOLTAGE

380 V

2.2. Standard Equipment

1 Bandsaw Blade

Hydromechanical Band Tension

Invertor

Adjustable Tension Band Wheel

Double way miter cutting ( Right side

60°, Left side 45° )

Fast Clamping Arm

Adjustable Length Setting Bar

2.6. Properties Table According to Metal

Sawdust

2.3. Noise Level

In accordance with the Machinery Directive

2006/42/EC

The A-weighted continuous acoustic

pressure does not exceed 70 dB (A).

The maximum level of the C-weighted

instantaneous acoustic pressure is always

less than 130 dB.

NOTE: With the machine operating, the noise

level will vary according to the different materials

being processed and setting up. The user must

therefore assess the intensity and if necessary

provide the operators with the necessary personal

protection.

2.4. Machine Dimensions

2.5. KMT 220 Craft DM Bandsaw Machine

Cutting Capacity

Filling

Shape of the

Filling

Thick, hard

and short

Thick, hard

and brittle

Thick, hard

and curled

Thick, hard

and curled

Thin, spiral

and curled

Thin, spiral

and curled

Like dust

Thin and

very curled

Colour of the

Filing

Blue or

brown

Blue or

brown

Silver or

yellow

Silver

Bandsaw Speed

Decrease

Suitable

Increase

Suitable

Decrease

Suitable

Advance Speed

Decrease

Decrease a

little

Decrease

Suitable

Increase

Decrease

The others

Control

lubricant

coolant

level

Control

lubricant

coolant level

Control

number of

teeth

Control

number of

teeth

Use thick

pitch saw

0°

45°

60°

-45°

220 mm

160 mm

95 mm

140 mm

200 mm

140 mm

95 mm

120 mm

180 x 250

140 x 150

75 x 95

90 x 150

3TRANSPORTATION AND

INSTALLATION

3.1. Handling the Unpacked Machine

Make sure the machine is safely loaded and

balanced when moving it with a forklift, failing to

do so may cause personal injury or damage to the

machine.

3.2. After Unpacking the Machine

Put the machine in a dry and sheltered place to

prevent damage to the electrical and mechanical

components. Apply appropriate lubricant

(machine oil or grease) on the slide ways and

non-painted areas to prevent rust.

3.3. Environmental Conditions

Mains voltage and frequency complying

with the machine motor characteristics.

Environment temperature from -10° C to

50° C

Relative humidity %10 to %90

3.4. Machine Placement and Position

The followings should be considered when

positioning the machine:

The floor: The machine should be placed on a

lecelled concrete floor.

Working Area: Sufficient space should be

allocated around the machine for comfortably

loading and unloading work stock and for easy

access during maintenance and repair. When

necessary, all doors and access panels should be

opened without interference.

Lighting: The machine and its surroundings

should be well lit for operator’s safety and for a

convenient operation and maintenance.

4 PREPARATION BEFORE

OPERATION

4.1. Cleaning

Unpainted and uncoated machine surfaces were

coated with a rust inhibitor prior to shipment. -

The rust inhibitor should be cleaned with an

appropriate solvent. To prevent rust on unpainted

surfaces, a light coat of machine oil can be

applied.

4.2. Lubricating

Lubricate all the sliding parts before starting.

4.3. Coolant

The machine is shipped with the coolant reservoir

empty. Fill the reservoir with coolant until it is

full. A sight gauge is mounted on the machine

base to check coolant level.

Caution: Do not run the coolant pump without

coolant in the reservoir. Otherwise, the coolant

pump will be damaged.

4.4. Electrical Power Connection

1. Electrical connection must be done by a

qualified electrician, in conformance with the

required electrical standards of your area.

2. Turn off the main circuit breaker of the area in

which the machine will be located.

3. Machine's power cord should be connected to

an appropriate power source; make sure the voltage

rate matches the one required for the machine.

4. It is important that the shipping brace should

be removed from the saw before taking any further

step.

Note: If the ‘emergency stop button’ is

depressed, it must be released for the machine to

run.

4.5. Final Inspection Checklist before

Operation

After installing the machine, a final inspection

should be performed by considering the following

checklist;

Any missing components, guards or panels

Removal of the shipping brace

Lost fasteners and fittings, hoses and

conduit

Missing or damaged items

Coolant, oil, or hydraulic leads

Tools and others materials left on saw

Safety measures, general condition and

readiness for use

5 OPERATION

In this section, the functions of the machine will

described to guide the operator to become familiar

with the machine and its components.

5.1ControlPanel

A) Main Power Switch

The machine is ready when the main power

switch is turned on.

B) Coolant Pump On/Off

Coolant pump switch on/off via this button.

Caution: Do not operate the coolant motor while

coolant tank empty. Otherwise, the coolant motor

will be damaged.

C) Open/Close Switch

Cutting process can be started and stopped with

these buttons.

D) Blade Speed Arrangement Button

Blade speed can be adjusted 25-90 m/min by this

button.

E) Emergency Stop Button

The "Emergency stop" push button stops all

functions of the machine. The machine will not

function until "Emergency stop button’ is

released. To release the emergency button, turn it

in the direction indicated on its hub.

Caution: The "Emergency stop" push button does

not disconnect the machine from the main power

supply. To avoid from serious injury or death due

to electricity shock, turn the main power switch off

or disconnect the machine from the main supply

before servicing it.

F) Bow Down Speed Valve

Bow down speed can be adjusted by this button.

5.2. Blade Changing Procedure

In order to achieve accurate and efficient cuts, it

is important to use a sharp and correct blade for

the material being cut.

1- Raise the saw frame to its highest position

2- Turn the hand-wheel to left to loosen the

blade.

3- Switch off the main power switch of the

machine.

Caution: Avoid serious injury by turning the

machine's power off at the main switch before

adjusting, servicing, or cleaning the saw.

4- Open all the wheel covers on the saw

frame.

5- Loosen the bolts on the carbide blade

guides. Lower the blade from bandsaw

guides.

6- Lower the chip brush away from the blade

by loosening the chip brush locking lever.

Caution: Wear heavy protective work gloves and

safety glasses when handling blades to avoid

injury.

7- Carefully remove the blade from the saw.

8- Uncoil the new blade and insert the blade

around the band wheels.

Warning: New blades are generally shipped in a

coiled from. This puts them under tension and can

suddenly be uncoiled. Take extreme caution to

revent injury when uncoiling the new blade. Make

sure you wear safety gloves and glasses. Locate

back of edge the blade into the carbide inserts

(pressure pads) and guide bearings so the teeth

point in downward direction.

9- Press the back edge of the blade firmly

against the back-up of the carbide guides

10- Turn on the main switch of the machine.

11- Turn the hand-wheel to right (to

tensioning position) to apply a light

pressure.

12- Press the back edge of the blade firmly

against the flange of each band wheel.

13- Turn the hand-wheel to right (tensioning

position) to exert sufficient tension on the

saw blade.

14- Turn off the main switch of the machine.

15- Turn the bolts clockwise to tighten the

carbide pressure pads against the blade.

Tighten the carbide guides by hand only.

Note: Do not over-tighten the carbide pressure

guides.

16- Adjust the position of the chip brush so

that the bristles reach fully into the gullet

of the blade without extending beyond.

Then lock the chip brush in place.

Important: Improper positioning of the chip

brush will result in excessive blade or chip

brush wear.

17- Make sure that you close and secure the

band wheel covers and blade guards at the

end of this process.

6 MAINTENANCE

The maintenance schedule is listed below on the

basis of daily, weekly, monthly and six-monthly

intervals. Utmost care should be given to the

maintenance. Poor maintenance or neglecting

some of its requirements will result in premature

machine failure and/or unsatisfactory

performance.

6.1.Daily Maintenance

Clean/empty the chip reservoir whenever

necessary.

Use suitable brush with soft bristles. Do

not use hard materials to clean the

machine.

Check whether the emergency stop button

functions properly. Check that the entire

wheel covers other safety guards are in

place and fixed properly.

Check the wear on the teeth of the saw

blade.

Check the level of coolant.

Don not use pressured air for cleaning the

machine; expect for unblocking the

coolant pipes.

6.2.Weekly Maintenance

Clean the wheels, vise, slides and

bearings.

Pull the movable jaws of the vise back

and clean the slides, beds and other

moving components and lubricate with

thin grease.

Apply grease to the main vise roller drive

mechanisms gearbox and vise roller

bearings. Check the condition of these

mechanisms and clean them if necessary

before applying grease. Use EP type

grease for vise roller drive mechanisms

gearbox.

Test the quality/condition of the coolant

and water/boron oil ratio; if necessary

renew it.

Non-painted parts should be wiped with a

clean cloth and oiled with protective

machine oil to prevent rust.

Coolant thank should be cleaned against

chips to prevent them accumulating onto

the floor of the tank.

6.3.Monthly Maintenance

Check the level of hydraulic oil from the

site gauge. If the level drops below

indicated min. line, add hydraulic

system oil of grade 46.

Check the conditions of saw blade guide

bearings and carbide pressure pads at the

ends of guide arms. They should be

replaced when they become worn or

loose.

Check the gaps in the bearings of the

wheels. Replace them if they are won.

Check the condition of hydraulic systems

(cylinder/pistons, pipes/hoses, sealants

and hydraulic couplings.)

6.4.Six-Monthly Maintenance

Perform all monthly maintenance checks

for six-monthly maintenance too. And

replaces those parts of the machine that

do not function as expected or that are

excessively worn.

Check the work stock feeding rollers for

wear and renew them if necessary.

Check the vise roller drive mechanisms

gearbox; renew the worn gear wheels if

necessary.

6.5.Periodic Maintenance

Renew the wheel bearings.

Renew the carbide pressure pads and the

saw blade guide bearings.

Check the viscosity/condition of the

hydraulic oil. Renew if it is necessary.

Check the worn/damaged/malfunctioning

components that do not function properly.

7 TROUBLESHOOTING

Some of the generally faced troubles and their possible causes and/or remedies are presented in the

following table.

PROBLEMS/FAULTS

POSSIBLE CAUSES AND REMEDIES

Non-straight cuts

Insufficient blade tension

Incorrect or loose work stock clamping

Use coarser blade pitch

High feed rate or pressure

Tooth set damage

Guide arms are loose or set too far apart

Premature blade

breakage, premature

tooth wear and

chipped tooth

Feed rate too high or too low

Check your coolant

Check/adjust carbide blade pressure pads

Check wheel alignment

Allow enough clearance before starting cut

Reduce band tension when the machine isn’t

operated

Cutting speed too high

Wrong tooth pitch

Incorrect or loose work stock clamping

Ineffective coolant application

Improper break-in period

Perform scheduled maintenance

Despite taking all necessary action, if a fault persists, you should call the service

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