Transcript
quantum MASCHINEN
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GERMANY
Operating manual Version 1.4
Metal belt saw S 181
GB
© 2003
Keep for future reference!
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 1
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Table of contents 1 Safety 1.1 1.2 1.3 1.4 1.5
1.6 1.7
1.8 1.9 1.10 1.11 1.12
1.13 1.14
Safety warnings (warning notes) ........................................................................................... 5 1.1.1 Classification of hazards ............................................................................................ 5 Other pictograms ................................................................................................................... 6 Proper use ............................................................................................................................. 6 Possible dangers caused by the metal belt saw .................................................................... 7 Qualification of personnel ...................................................................................................... 7 1.5.1 Target group ............................................................................................................... 7 1.5.2 Authorised personnel ................................................................................................. 8 User positions ........................................................................................................................ 9 Safety devices ....................................................................................................................... 9 1.7.1 EMERGENCY button ................................................................................................. 9 1.7.2 Protective cover for V-belt ........................................................................................ 10 1.7.3 Saw arch .................................................................................................................. 10 "Forbidden", Warning and Information labels ...................................................................... 11 Safety check ........................................................................................................................ 11 Individual protection gear ..................................................................................................... 12 Safety during operation ........................................................................................................ 12 Safety during maintenance .................................................................................................. 13 1.12.1 Disconnecting the metal belt saw and making it safe ............................................... 13 1.12.2 Using lifting equipment ............................................................................................. 14 1.12.3 Mechanical maintenance work ................................................................................. 14 Accident report ..................................................................................................................... 14 Electrical system .................................................................................................................. 14
2 Technical data 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10
Characteristics plates .......................................................................................................... Power connection ................................................................................................................ Cutting field .......................................................................................................................... General ................................................................................................................................ Dimensions .......................................................................................................................... Speed of saw blade ............................................................................................................. External conditions .............................................................................................................. Operating material ............................................................................................................... Cooling pump ....................................................................................................................... Emissions ............................................................................................................................
15 15 15 15 15 16 16 16 16 16
3 Assembly 3.1 3.2 3.3
3.4 3.5
Parts list ............................................................................................................................... Storage ................................................................................................................................ Installation and assembly .................................................................................................... 3.3.1 Requirements of installation site .............................................................................. 3.3.2 Assembly .................................................................................................................. First use ............................................................................................................................... Checking .............................................................................................................................. 3.5.1 Saw belt guide bearings ........................................................................................... 3.5.2 Tension of the saw belt ............................................................................................ 3.5.3 Power supply ............................................................................................................
17 17 17 17 17 19 19 19 19 20
4 Design and function
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Hydraulic feed ...................................................................................................................... Saw belt guide ..................................................................................................................... Work-holder vice .................................................................................................................. Tension of the saw belt ........................................................................................................ Speed of the saw belt .......................................................................................................... End stop switch .................................................................................................................... Pressure of the saw arch ..................................................................................................... Belt guide bearings .............................................................................................................. Liquid cooling system ..........................................................................................................
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4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9
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5 Handling 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8
Safety .................................................................................................................................. Control and indicating elements .......................................................................................... Inserting the work piece ...................................................................................................... 5.3.1 Increasing the holding capacity ............................................................................... Adjusting the saw belt guide ............................................................................................... Adjusting the speed of the saw belt .................................................................................... 5.5.1 Table of revolutions ................................................................................................ Liquid cooling system .......................................................................................................... Starting the metal belt saw .................................................................................................. Hydraulic feed .....................................................................................................................
25 25 26 27 27 27 28 28 29 29
6 Maintenance 6.1
6.2 6.3 6.4 6.5 6.6
Safety .................................................................................................................................. 6.1.1 Preparation .............................................................................................................. 6.1.2 Restarting ................................................................................................................ Revision and maintenance .................................................................................................. Repair .................................................................................................................................. Wiring diagram .................................................................................................................... Exploded view 1 .................................................................................................................. Exploded view 2 .................................................................................................................. 6.6.1 Spare parts list - metal belt saw ...............................................................................
30 30 31 31 37 38 39 40 41
7 Anomalies 7.1
Anomalies in the metal belt saw .......................................................................................... 44
8 Appendix 8.1 8.2 8.3 8.4
Copyright ............................................................................................................................. Terminology/Glossary ......................................................................................................... Product follow-up ................................................................................................................ EC Declaration of Conformity ..............................................................................................
45 45 46 47
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9 Index
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Safety Explanation of the display Reference to another page in this manual Calls on you to act Enumerations
• This section of the operating manual • • • •
explains the meaning and use of the warning references contained in the operating manual, states the instructions with regard to the operation of the metal belt saw, warns you on the dangers to you and third parties, which could occur in the event the instructions in this manual are not observed, informs you on measures that help prevent hazard.
In addition to this operating manual please observe • • •
applicable laws and regulations, legal regulations for accident prevention, the danger, warning and mandatory signs such as the warning reference on the metal belt saw.
During installation, operation, maintenance and repair of the metal belt saw the European standards are to be observed. With regard to relevant national legislation which has not yet been adjusted to the European standards, the applicable national legislation is to be observed. If applicable, the relevant precautions, as to be observed in accordance with the national rules and regulations, are to be adhered to, prior to operating the metal belt saw. THE DOCUMENTATION IS TO BE KEPT NEAR THE METAL BELT SAW, FOR POSSIBLE FUTURE REFERENCE. INFORMATION In the event this operating manual does not offer a solution to your problem, please feel free to contact: OPTIMUM Maschinen GmbH Dr. Robert-Pfleger-Str. 26 D- 96103 Hallstadt, Germany
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19 December 2005
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Safety
MASCHINEN
1.1
Safety warnings (warning notes)
1.1.1
Classification of hazards
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We classify the safety warnings into various levels. The table below gives an overview of the classification of symbols (pictograms) and warnings for the specific danger and its (possible) consequences. Pictogram
Alarm expression
Definition/Consequences
DANGER!
Imminent danger that will cause serious injury or death to personnel.
Warning!
Risk: A danger that might cause serious injury or death to personnel.
CAUTION!
Danger or unsafe procedure that might cause injury to personnel or damage to property. Situation that could cause damage to the machine and product and other types of damage.
ATTENTION!
No risk of injury to personnel.
Application tips and other important or useful information and notes. INFORMATION
No dangerous or harmful consequences for personnel or objects.
In the case of specific dangers, we replace the pictogram
with a warning of
injuries to hands,
hazardous electrical voltage,
rotating parts.
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General danger
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1.2
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Other pictograms
1.3
Warning of automatic start-up!
Activation forbidden!
Disconnect the plug from the mains!
Use protective goggles!
Use ear protection!
Use protective gloves!
Use protective boots!
Wear a safety suit!
Protect the environment!
Contact address
Proper use Use WARNING! Improper use of the metal belt saw • will endanger personnel, • will endanger the machine and other items used by the operator, • may affect proper operation of the machine. The machine is designed and manufactured to be used in environments in which there is no potential danger of explosion. The machine is designed and manufactured to saw cold metals, cast materials and plastics or other materials that are not harmful to health and do not generate dust. The metal belt saw must not be used on wood. The pieces to be cut must be of a shape that will allow them to be securely attached in the workholder vice and ensure that the piece does not come loose when it is being sawed. The metal belt saw must only be installed and operated in a dry and well-ventilated place.
Improper use!
If the metal belt saw is used in any way other than as described above, if it is modified without the authorisation of Optimum Maschinen GmbH or if it is operated with different process data, then it is being used improperly. We do not take liability for damage caused by improper use. We would like to stress that any modifications to the construction, or technical or technological modifications which have not been authorised by Optimum Maschinen GmbH will also render the guarantee null and void. It is also part of proper use that • • •
the limits of the metal belt saw are complied with, the instruction manual is observed, review and maintenance instructions are observed. “Technical data“ on page 15
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The decisive factor for achieving efficient cutting and the necessary angular tolerance is the correct choice of parameters such as the saw belt, feed, cutting pressure, cutting speed and cooling agent.
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WARNING! Very serious injury. It is forbidden to make any modifications or alterations to the operating values of the metal belt saw! These could endanger personnel and cause damage to the metal belt saw.
1.4
Possible dangers caused by the metal belt saw The metal belt saw has undergone a safety inspection (analysis of danger with assessment of risks). Design and construction based on this analysis were carried out with the latest technological advances. Nonetheless, there remains a residual risk, since the metal belt saw operates • •
with electrical voltage and current, with a continuous saw belt.
We have used construction resources and safety techniques to minimise the health risk to personnel resulting from these hazards. If the metal belt saw is used by personnel who are not duly qualified, there may be a risk resulting from incorrect operation or unsuitable maintenance. INFORMATION All personnel involved in assembly, commissioning, operation and maintenance must • •
be duly qualified, follow this instruction manual.
Disconnect the machine whenever cleaning or maintenance work is being carried out.
WARNING! THE metal belt saw MAY ONLY BE USED WITH THE SAFETY DEVICES ACTIVATED. Disconnect the metal belt saw whenever you detect a failure in the safety devices or when they are not fitted! All additional installations carried out by the operator must incorporate the prescribed safety devices. As the machine operator, this will be your responsibility! “Safety devices“ on page 9
1.5
Qualification of personnel
1.5.1
Target group This manual is addressed to • • •
operators, users, maintenance stuff.
The warning notes therefore refer to both operation and maintenance of the metal belt saw. Determine clearly and unequivocally who will be responsible for the different activities on the machine (use, maintenance and repair). Vague or unclear assignment of responsibilities constitutes a safety hazard!
GB
© 2003
Always disconnect the metal belt saw plug from the mains. This will prevent it being used by unauthorised personnel.
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1.5.2
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Authorised personnel WARNING! Incorrect use and maintenance of the metal belt saw causes danger for personnel, objects and the environment. Only authorised personnel may operate the metal belt saw! Personnel authorised to use and perform maintenance are the trained and instructed technical staff working for the operator and manufacturer.
The operator must Obligations of the operator
• •
• • • •
train staff, instruct staff regularly (at least once a year) on - all safety standards that apply to the machine, -
operation,
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accredited technical guidelines,
check staff's understanding, document training/instruction, require staff to confirm participation in training/instruction by a signature, check whether the staff are aware of safety and of dangers in the workplace and whether they observe the instruction manual.
The user must Obligations of the user
• • •
have received training in operation of the metal belt saw, know the function and principle of operation, before the machine is first used - have read and understood the instruction manual, -
additional qualification requirements
be familiar with all safety devices and regulations.
For work on the following machine components there are additional requirements: •
Electrical machine: Only an electrician or person working under the instructions and supervision of an electrician. Before carrying out work on electric components or operating units the following measures must be taken in the order given. - Disconnect all poles -
Ensure that the machine cannot be turned on again
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Check that there is no voltage
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1.6
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User positions The user must stand beside the metal belt saw. INFORMATION The main plug of the metal belt saw must be accessible.
1.7
Safety devices Use the metal belt saw only with properly functioning safety devices. Stop the metal belt saw immediately if there is a failure in the safety device or if it gets ineffective. It is your responsibility! If a safety device has been activated or has failed, the metal belt saw must only be used when • •
the cause of the failure has been removed, it has been verified that there is no resulting danger for personnel or objects.
WARNING! If you bypass, remove or override a safety device in any other way, you are endangering yourself and other personnel working with the metal belt saw. The possible consequences are • damage as a result of components or parts of components flying off at high speed, • contact with rotating parts, • fatal electrocution, The metal belt saw includes the following safety devices: • • •
1.7.1
Power switch (I / O) with an EMERGENCY function Protective cover for the V-belts Saw blade casing with protective cover at the rear.
EMERGENCY button The metal belt saw is fitted with an EMERGENCY button.
EMERGENCY button pressed down
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Illustr.1-1: EMERGENCY button
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1.7.2
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Protective cover for V-belt
Cover
Illustr.1-2: Protective cover for V-belt
1.7.3
Saw arch The arch of the metal belt saw is fitted with a protective cover firmly screwed onto the rear. The protective cover protects the belt guide pulleys and the rotating saw blade.
Saw arch
WARNING! Danger of injury! The teeth of the saw belt are sharp. Take great care when removing the rear cover to change the saw belt. Illustr.1-3: Saw blade casing
Close and screw down all protective covers before restarting the metal belt saw.
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"Forbidden", Warning and Information labels INFORMATION All warning labels must be legible. Check them regularly.
Positions of labels on the metal belt saw
Illustr.1-4: Metal belt saw
1.9
Safety check Check the metal belt saw at least once per shift. Inform the person responsible immediately of any damage, defect or change in operating function. Check all safety devices • • •
at the beginning of each shift (with the machine stopped), once a week (with the machine in operation), after every maintenance and repair operation.
Check that "Forbidden", Warning and Information labels and the markings on the metal belt saw • •
can be identified (if not, clean them), are complete.
INFORMATION Use the following table for checking.
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© 2003
General check Equipment
Check
Protective covers
Fitted, firmly bolted and not damaged
Date: 19 December 2005
OK
Checked by (signature):
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General check Equipment
Check
Labels, markings
Installed and legible
Date:
OK
Checked by (signature):
Run test Equipment
Check
EMERGENCY button
The metal belt saw must disconnect when the EMERGENCY button is activated.
Date:
1.10
OK
Checked by (signature):
Individual protection gear For specific work, equipment for personal protection as protection equipment is required. This includes: • • • • •
a safety helmet, protective goggles or face guard, safety gloves, safety shoes with steel toe cap, ear protection.
Before starting work check that the proper gear is available in the workplace. CAUTION! Dirty or contaminated body protection gear can cause disease. Clean your individual protection gear • each time after it has been used, • regularly, at least once a week.
Individual protection gear for special work Protect your face and eyes: During all work, and specifically work during which your face and eyes are exposed to hazard, a safety helmet with a face guard should be worn.
Use safety gloves when you lift or handle sharp-edged components manually.
Wear safety shoes when you position, dismantle or transport heavy components.
1.11
Safety during operation In the description of work with and on the metal belt saw we highlight the dangers specific to that work.
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WARNING! Prior to activating the metal belt saw please double-check whether this will • not lead to any danger with respect to people, • not cause any damage to equipment. Avoid unsafe working practises: • • • • • • •
1.12 Report and document any changes
1.12.1
Check that no one can be endangered as a result of the work to be initiated. The instructions in this manual must be observed during assembly, handling, maintenance and repair. Do not work on the grinder if your concentration is reduced, for example, because you are taking medication. Observe the rules for preventing accidents issued by your association for the prevention of occupational accidents and safety in the workplace or other inspection authorities. Stay at the metal belt saw until all rotating parts have come to a halt. Use prescribed protection gear. Make sure to wear a well-fitting work suit and, where necessary, a hairnet. Inform the inspector of any danger or failure.
Safety during maintenance Inform operators timely on maintenance and repair work. Report all safety relevant changes or performance details of the metal belt saw. Document all changes, have the operation manual changed accordingly and train the machine operators.
Disconnecting the metal belt saw and making it safe Unplug the machine from the mains before beginning any maintenance or repair work. Place a warning sign on the machine.
WARNING! Before reconnecting the plug to the mains, make sure that the metal belt saw's power (I / O) switch is in the OFF (O) position". If in doubt, press the EMERGENCY button before re-connecting the mains plug to the power supply.
EMERGENCY button pressed down
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Illustr.1-5: EMERGENCY button
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1.12.2
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Using lifting equipment WARNING! Use of unstable lifting and load suspension gear that breaks under load can cause very serious injuries or even death. Check that the lifting and load suspension gear • is of sufficient load capacity, • is in perfect condition. Observe the rules for preventing accidents issued by your association for the prevention of occupational accidents and safety in the workplace or other inspection authorities. Hold the loads properly. Never walk under suspended loads!
1.12.3
Mechanical maintenance work Remove all protection and safety devices before beginning maintenance work and re-install them once the work has been completed. These include: • • •
Covers Safety indications and warning signs Earth (ground) connection.
If you remove protection or safety devices, refit them immediately after completing the work. Check that they are working properly!
1.13
Accident report Inform your superiors and Optimum Maschinen GmbH immediately in the event of accidents, possible sources of danger and any actions which almost led to an accident (near misses). There are many possible causes. The sooner they are notified, the faster the causes can be eliminated. INFORMATION In the description of work with and on the drill we highlight the specific dangers of this work.
1.14
Electrical system Have the machine and/or the electric equipment checked regularly, and at least every six months. Eliminate immediately all defects such as loose connections, defective wires etc. A second person must be present during work on live components, to disconnect the power in the event of an emergency. Disconnect the metal belt saw immediately if there are any anomalies in the power supply! “Maintenance“ on page 30
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Technical data
MASCHINEN
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Technical data
2.1
Characteristics plates
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Illustr.2-1: Characteristics plate The following information gives the dimensions and weight and is the manufacturer's authorised machine data.
2.2
2.3
2.4
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Power connection
“Wiring diagram“ on page 38
Total connection rate
3 x 400 V; 50 Hz; 0.75 kW
Permitted voltage tolerance
380 V - 420 V
Protection mode
IP 54
Cutting field 90° round, max. (mm)
178
90° rectangular, max. (mm)
178 x 240
45° round, max. (mm)
110
45° rectangular, max. (mm)
170 x 110
Cutting angle
0° - 45°
General Cutting angle adjustment
using the adjustable clamps on the vice
Saw belt guide
Inversion pulleys supported on ball bearings
Raising the saw arm
Manually
Feed
The descent speed can be adjusted using a hydraulic cylinder with continuous advance
Tension of saw blade
Manually using the hand wheel
Dimensions Length [mm]
1295
Height [mm]
1060
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Technical data
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2.5
Dimensions Height of work area [mm]
1650
Width [mm]
450
Total weight [kg]
130
Dimensions of the saw belt [mm]
2362 x 19 x 0.9
2.6
Speed of saw blade by means of V-belt pulleys [m/min]
2.7
21 33.5 45 50
External conditions
2.8
Temperature
5-35 °C
Humidity
25 - 80 %
Operating material Support cylinder
Hydraulic oil, viscosity 32 - 46 as per DIN 51519 HLP Quality
Helical gear
Mobil 629
Spindle of the work-holder vice
Commercial heavy grease
Friction bearing
Commercial heavy grease
Liquid cooling system
Commercial lubricant and cooling agent
2.9
2.10
Cooling pump Power
3 x 400 V ; 50 Hz; 90 W
Turning speed [rpm]
2850
Volume of tank [litres]
10
Emissions The development of noise (sound pressure level) of the metal belt saw could, at the workplace, exceed the level of 73 dB(A). INFORMATION We recommend the use of sound insulation and ear protection.
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The duration of the noise pollution, the type and characteristics of the working area, such as other machines which are operated simultaneously, influence the development of noise at the workplace. Since Optimum Maschinen GmbH has no knowledge of the positioning area of the metal belt saw, the organisation responsible for the operation is to ensure all noise isolation measurements.
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Assembly
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Assembly INFORMATION The metal belt saw comes pre-assembled.
3.1
Parts list When the machine is delivered, check immediately that the metal belt saw has not been damaged during shipping and that all components are included. Also check that the set screws are loosened. • • • • • • • •
3.2
Metal belt saw Saw belt 2x Wheels, 1x Wheel axle, 2x Split pin 1x Transportation grip 1x pedestal Liquid cooling system Depth stop Instruction manual
Storage ATTENTION! Improper storage may cause important parts to be damaged or destroyed. Store packed or unpacked parts only under the following ambient conditions. nal conditions“ on page 16
“Exter-
Consult Optimum Maschinen GmbH if the metal belt saw and accessories have to be stored for a period of over three months or under different external conditions to those given here.
3.3
Installation and assembly
3.3.1
Requirements of installation site Organise the workplace around the metal belt saw in accordance with local safety regulations.
“Dimensions“ on page 15 Operation, maintenance and repair in the work area must not be hindered.
INFORMATION The mains plug of the metal belt saw must be accessiblemetal belt saw.
3.3.2
Assembly ATTENTION!
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Danger of crushing and overturning. Proceed with caution during the work described below.
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Assembly
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Wheels Place wooden chocks beneath the lower frame for fitting the wheels. Make sure the metal belt saw is located on a sturdy base. Cotter
Pass the axles through the holes in the lower frame. Position the wheels on the axles and attach them in place using cotter pins.
Illustr.3-1: Wheel
Standfoot and Transporthandle Assemble the transporthandle and the standfoot using the enclosed assembly material. Transporthandle
Standfoot
Abb.3-2: Transporthandle and Standfoot
Depth stop Position the stop rod in the hole and immobilise it with the lockscrew. Push the saw stop onto the stop rod.
Fastening screw Bore hole
Lock the saw stop using the set stop. Saw stop Stop rod Set stop
Illustr.3-3: Depth stop
Shipping guard Remove the shipping guard.
Saw arch
Replace the shipping guard with the end stop buffer supplied with the machine for the saw arch. End stop buffer
Limit stop switch
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Illustr.3-4: End stop buffer
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Assembly
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3.4
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First use WARNING! Personnel and equipment may be endangered if the metal belt saw is first used by inexpert personnel. We do not take responsibility for damage caused by incorrect commissioning.
3.5
Checking Check the following. ATTENTION! Danger of cutting! Proceed with caution during the work described below. Use the prescribed protection equipment. Direction of the saw teeth Check the direction of the saw teeth. They should be oriented towards the drive motor. Drive motor
Inspecting the belt guide pulleys Belt guide pulley
Check that the saw blade is in the right position on the belt guide pulleys.
“Aligning the saw belt“ on page 34
Illustr.3-5: Belt guide pulley
3.5.1
Saw belt guide bearings Check that the saw belt fits snugly inside the guide bearings.
“Adjusting the belt guide bearings“ on page 33
Guide bearings
Illustr.3-6: Belt guide bearings
3.5.2
Tension of the saw belt
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© 2003
Check the tension of the saw belt. The tension in the saw belt is correct if the middle can be pushed down 3 mm with a force of approximately 50 N. “Tension of the saw belt“ on page 22
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3.5.3
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Assembly
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Power supply Connect a CEE-400V-16A plug
Modify the polarity at the terminal counter of the combined switch/plug with a screwdriver if the direction of the saw belt is wrong.
polarity switch Plug
Illustr.3-7: Combined switch/plug
ATTENTION! Please pay attention that all three phases (L1, L2, L3) are connected correctly. Most engine failure result from incorrect connection, for instance the neutral conductor ( N ) is being connected to a phase. This might lead to the following results: - The engine does get quickly very hot. - The engine noise increases, i.e. becomes louder. - The engine has no power. When the phases are connected wrongly, the guarantee is being null and void.
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Design and function
MASCHINEN
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Design and function It is possible to saw multiple materials with the metal belt saw. The metal belt saw is designed for sawing up to: • • • •
178mm in round pieces at a sawing angle of 90° 178mm x 240mm in rectangular pieces at a sawing angle of 90° 110mm in round pieces at a sawing angle of 45° 170mm x 110mm in rectangular pieces at a sawing angle of 45°
The speed of the saw belt can be altered by shifting a V-belt onto pulleys with different diameters. Four speeds may be selected which allow a wide range of materials to be sawed. The clamps of the work-holder vice can be adjusted in a field of 45° to 90° to allow angular sawing. A hydraulic cylinder with a manually adjustable feed regulation valve acts as the feed adjustment system for the saw arch. The tension of the saw blade is regulated using a hand wheel.
4.1
Hydraulic feed The saw arch is advanced by means of the hydraulic cylinder. The hydraulic oil is fed to another chamber by the feed regulation valve in the cylinder.
Feed regulation valve Stop valve
Illustr.4-1: Hydraulic feed
4.2
Saw belt guide The adjustable guide for the saw belt and flexible tube for the cooling agent can be used to adjust the free distance when sawing small parts.
Saw belt guide
Illustr.4-2: Saw belt guide
ATTENTION!
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© 2003
An unnecessarily wide space between the work piece and the saw belt guide, in combination with a high feed rate very quickly causes the saw blade to wear down.
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4.3
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Design and function
GERMANY
Work-holder vice The work-holder vice is used for securing the work piece. The work-holder vice consists of • • •
Front clamp
the work table, the adjustable clamps, the securing system with wheel.
Rear clamp
Work table
Illustr.4-3: Work-holder vice
For angular cuts, the clamps on the workholder vice can be adjusted with a continuous advance to a maximum of 45°.
Clamps
Fixing nut
Illustr.4-4: Angular cut
By moving the rear clamp you can enlarge the securing capacity of the work-holder vice. Rear clamp
Illustr.4-5: Rear clamp
4.4
Tension of the saw belt The tension in the saw belt can be adjusted by means of a hand wheel. The position of the belt guide pulley can be adjusted using a screw rod.
Saw arch Hand wheel
Illustr.4-6: Tension of the saw belt
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Design and function
MASCHINEN
4.5
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Speed of the saw belt The speed of the saw belt can be altered by changing the V-belt in the pulleys.
Protection cover
V-belt
ATTENTION! Make sure that the tension of the V-belt is correct.
Motor Fastening screws
If the tension is too great or too little it can cause damage. Illustr.4-7: Speed of the saw belt
4.6
End stop switch The end stop switch disconnects the metal belt saw in the bottom position.
End stop switch End stop buffer
Illustr.4-8: End stop switch
4.7
Pressure of the saw arch The pressure of the saw arch is regulated by means of a spring. A coil spring compensates for the force. If the pressure of the saw arch is badly set, it can case curved cuts, breakage of teeth, deformation, and breakage of the belt guide pulleys.
Spring
Screw
Illustr.4-9: Coil spring
4.8
Belt guide bearings ATTENTION! Screws
GB
© 2003
This metal belt saw is designed to use saw blades of 2,362 x 19 x 0.9 mm. Use of other saw blades could cause damage to the saw.
Illustr.4-10: Belt guide bearings
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 23
quantum MASCHINEN
4.9
-
Design and function
GERMANY
Liquid cooling system The sawing movement produces high temperatures in the edge of the tool due to the friction generated. The tool must therefore be cooled during operation. Using a suitable lubricant or cooling agent leads to better results and longer saw belt life.
Illustr.4-11: Liquid cooling system
INFORMATION We recommend that you use a water-soluble and non-pollutant sawing emulsion as a cooling agent. This can be acquired from authorised distributors. Make sure to clean up the cooling agent after use. Respect the environment when disposing of any lubricants and cooling agents. Follow the manufacturer’s disposal instructions.
© 2003
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 24
quantum
Handling
MASCHINEN
5
Handling
5.1
Safety
-
GERMANY
Use the metal belt saw only under the following conditions:
• • • •
The metal belt saw is in proper working order. The metal belt saw is used as prescribed. Follow the instruction manual. All safety devices are installed and activated.
All anomalies should be eliminated immediately. Stop the machine immediately in the event of any abnormality in operation and make sure it cannot be started up accidentally or without authorisation. Notify the person responsible immediately of any modification.
“Safety during operation“ on page 12
5.2
Control and indicating elements Saw belt tension
Swivelling clamps Combined plug-switch with emergency button
Saw arch
Flexible cooling tube and adjusting valve
On-off switch for cooling pump
Adjustable guide for saw belt and flexible cooling tube
Feed regulation valve Hydraulic cylinder
Hand wheel for work-holder vice
GB
© 2003
Illustr.5-1: Metal belt saw S 181
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 25
quantum MASCHINEN
5.3
-
Handling
GERMANY
Inserting the work piece Raise the saw arch. Place the closing tap in vertical position to secure the arch in a given position. Closing tap
Illustr.5-2: Hydraulic feed
Place the piece to be cut in the work-holder vice.
ATTENTION!
Front clamp
Danger of overturning of the metal belt saw. Support long work pieces before pushing the piece to be cut into the work-holder vice.
Rear clamp
Work table
Illustr.5-3: Work-holder vice
WARNING! Disconnect the metal belt saw from the mains if you are making angular modifications to the clamps or increasing the holding capacity of the work-holder vice. For angular cuts, the clamps on the workholder vice can be adjusted with a continuous advance to a maximum of 45°.
Clamps
Fixing nut
Illustr.5-4: Angular cut
Secure the piece between the clamps by turning the hand wheel.
Illustr.5-5: Hand wheel
© 2003
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 26
quantum
Handling
MASCHINEN
5.3.1
-
GERMANY
Increasing the holding capacity Disconnect the metal belt saw from the mains. Unscrew the bolts on the rear clamp. Set the clamp at a greater distance in the holes provided.
Screws Bore holes
Screw the clamp back in.
Illustr.5-6: Rear clamp
ATTENTION! Re-tighten the clamps after any change in the angle or position.
5.4
Adjusting the saw belt guide Change the position of the saw belt guide depending on the size of the pieces to be cut.
Setscrews
Loosen the setscrews. Place the saw belt guide near the work piece without affecting or hindering the sawing process. Re-tighten the setscrews.
Illustr.5-7: Setscrews
ATTENTION! An unnecessarily wide space between the work piece and the saw belt guide, in combination with a high feed rate very quickly causes the saw belt to wear down.
5.5
Adjusting the speed of the saw belt WARNING! Do not open the protective cover until you have disconnected the metal belt saw from the power supply. Close and screw down the protective cover after any adjustment to the turning spee. Disconnect the metal belt saw from the mains. Loosen the securing screws on the motor plate until you can move it to reduce the tension in the V-belt. Place the V-belt in the required position on the pulleys.
Protective cover
V-belt Motor Fastening screws
GB
© 2003
Tighten the V-belt by moving the motor back.
Illustr.5-8: Saw belt speed
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 27
quantum MASCHINEN
-
Handling
GERMANY
Check the tension in the V-belt. The tension in the V-belt is correct if you can push it approximately 1 cm with your finger. Re-tighten the securing screws of the motor plate and connect the metal belt saw to the power supply. Close and screw down the protective cover.
ATTENTION! Make sure that the tension of the V-belts is correct. If the tension is too great or too little it can cause damage.
5.5.1
Table of revolutions Spindle
Motor
50 45 33,5 21
Illustr.5-9: Table of revolutions
Saw belt speeds Guidelines values for cutting speeds [m / min] : Material
[m / min]
Special steel
[m / min]
Medium and high-alloy carbon steel
Tool steel Chromenickel steel
Material
21
Material
[m / min]
Low-alloy carbon steel 33, 5
[m / min]
Material
Aluminium 45
50
Hard brass Soft brass
Plastic
Bronze
ATTENTION! If you use bimetallic saw belts, you must readjust the saw belt guides
5.6
Liquid cooling system ATTENTION! Failure of the pump in the event of a dry run. The pump is lubricated by the cooling agent. Do not start up the pump without cooling agent.
Illustr.5-10: Cooling pump
© 2003
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 28
quantum
Handling
MASCHINEN
-
GERMANY
INFORMATION We recommend that you use a water-soluble and non-pollutant sawing emulsion as a cooling agent. This can be acquired from authorised distributors. Make sure to clean up the cooling agent after use. Respect the environment when disposing of any lubricants and cooling agents. Follow the manufacturer's disposal instructions. Turn on the liquid cooling system with the switch.
Liquid cooling system switch
Illustr.5-11: Liquid cooling system switch
5.7
Starting the metal belt saw Lift the cover over the EMERGENCY button and start the metal belt saw by pressing the green button. Push down the cover of the EMERGENCY button to ensure the EMERGENCY function is operative. Do not close the cover completely, as that will activate the EMERGENCY function.
Illustr.5-12: Power Switch (I / O)
5.8
Hydraulic feed Adjust the descent speed of the saw arch in the feed regulation valve. Open the shutoff tap.
The belt saw is disconnected automatically once it reaches the end of the run.
Feed regulation valve Shutoff tap
Follow the same steps in reverse order to remove the work piece from the vice.
Illustr.5-13: Hydraulic feed
EMPIRICAL RULE!
GB
© 2003
The finer the tooth spacing and/or the thinner or smaller the work piece, the lower the feed should be.
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 29
quantum MASCHINEN
6
-
Maintenance
GERMANY
Maintenance In this chapter you will find important information about • • •
Inspection Maintenance Repairs
of the metal belt saw. NOTICE ! Properly-performed regular maintenance is an essential prerequisite for • safe operation, • fault-free operation, • long service life of the metal belt saw and • the quality of the products you manufacture. Installations and equipment from other manufacturers must also be in optimum condition.
ENVIRONMENTAL PROTECTION Make sure that liquid and oils are not spilt on the ground. Clean up any spilt liquid or oils immediately using proper oil-absorption methods and dispose of them in accordance with current legal requirements on the environment.
Cleaning up spillages Do not re-introduce liquids spilt outside the system during repair or as a result of leakage from the reserve tank: collect them in a collecting vessel to be disposed of.
Disposal Never dump oil or other pollutant substances in water inlets, rivers or channels. Used oils must be delivered to a collection centre. Consult your superior if you do not know where the collection centre is.
6.1
Safety WARNING! The consequences of incorrect maintenance and repair work may include: • Very serious injury to personnel working on the metal belt saw, • Damage to the metal belt saw. Only qualified personnel should carry out maintenance and repair work on the metal belt saw. Use the prescribed protection equipment.
6.1.1
Preparation WARNING! Only carry out work on the metal belt saw if it has been unplugged from the mains power supply.
© 2003
“Disconnecting the metal belt saw and making it safe“ on page 13 Position a warning sign.
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 30
quantum
Maintenance
MASCHINEN
6.1.2
-
GERMANY
Restarting Before restarting run a safety check.
“Safety check“ on page 11
WARNING! Before connecting the metal belt saw you must check that • there is no danger for personnel, • the metal belt saw is undamaged.
6.2
Revision and maintenance The type and extent of wear depends to a large extent on the individual usage and service conditions. For this reason, all the intervals are only valid for the authorised conditions.
Intervals / When ?
Where ?
What ?
How ? Place a set square in the work-holder vice and compare the position. Using the set square, check whether the saw belt is parallel to the angle.
as required
Saw belt guide
Loosen the screws on the saw belt guide if the angle is incorrect and adjust the belt guide accordingly.
INFORMATION Adjusting the position of the saw belt guide with respect to the work table
Check the adjustments with a thin test cut.
Srews
Work table
Illustr.6-1: Saw belt guide
Place a set square in the clamp to be adjusted. Check the required angle between clamp and saw blade.
as required
Work-holder vice
Loosen the checknuts on the clamp in question if the angle is incorrect and adjust the clamp accordingly. Clamp
Adjusting the position of the clamps with respect to the saw belt
Fixing nut
Saw belt
GB
© 2003
Illustr.6-2: Clamps
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 31
quantum MASCHINEN
Intervals / When ?
-
Maintenance
GERMANY
Where ?
What ?
How ? Turn the hand wheel clockwise to increase the tension in the saw belt. The saw belt is at the right tension if it can be moved 3 mm in the centre applying a force of approximately 50 N.
as required and after change of saw belt
Saw arch
Hand wheel
Adjusting the tension in the saw belt
Illustr.6-3: Saw belt tension
ATTENTION! Do not strain the saw blade more than necessary. The blade could be overstretched and become warped. Place the saw arch in vertical position and close the shutoff tap on the hydraulic cylinder. Place a level in the work-holder vice. Let the saw arch descend slowly. Fully open the shut-off tap on the hydraulic cylinder once the saw belt has made contact with the level. The support force of the saw arch on the level should come to 5 - 6 kg. Saw arch
If there have been curved cuts, breakage of teeth, deformations or a breakage in the belt guide pulleys
Adjusting the pressure of the saw arch
If necessary, correct the value by changing the position of the spring using the screw rod.
Spring
Screw rod
Illustr.6-4: Saw arch pressure
© 2003
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 32
quantum
Maintenance
MASCHINEN
Intervals / When ?
Where ?
What ?
-
GERMANY
How ? Place the saw arch in vertical position and close the shutoff tap on the hydraulic cylinder. Regulate the belt guide bearings so that the saw blade cannot move, but the belt guide bearings can still be removed by hand.
as required
Saw belt guide
Loosen the locknut on the locating screws and turn the locating screws until the distance of the guide bearings has been corrected.
Adjusting the belt guide bearings
Locating screws Belt guide bearing Allen screw
Illustr.6-5: Saw belt guide bearings
ATTENTION! Check that the teeth on the saw belt do not collide with the guide bearings. Turn the end stop buffer up or down or correct the end stop tab so that it comes into contact with the end stop switch at the end of the sawing process.
If the metal belt saw keeps lowering after the sawing process is complete.
End stop switch lug End stop switch
Adjusting the end stop switch
If the metal belt saw disconnects before the sawing process is complete
End stop buffer
after each maintenance or repair operation
“Safety check“ on page 11
Lubricate Bearing
GB
© 2003
every week
Drive shaft
Start of shift
Metal belt saw
Illustr.6-6: End stop switch
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 33
quantum MASCHINEN
Intervals / When ?
-
Maintenance
GERMANY
Where ?
What ?
How ? Check the oil level of the helical gear.
every month
Helical gear
Visual inspection
every six months
V-belt
INFORMATION
Visual inspection
During the first few days in service, the helical gear may become quite hot. If the temperature does not exceed 70ºC, no further measures need be taken. This running-in process can improve considerably if a little Molykote G-n gear paste is added to the oil in the helical gear before the machine is first used. This reduces wear in the flanks of the teeth and increases the useful service life of the gear. Check for porosity and wear in the belt
Place the saw arch in vertical position and close the shutoff tap on the support cylinder. Check the tension of the saw belt. sion in the saw belt“ on page 32
“Adjusting the ten-
Remove the protective cover from the saw arch. Activate the metal belt saw and check that the saw belt runs correctly through the belt guide pulleys. Loosen the securing screws and turn the setscrews while observing how the saw belt runs.
as required
Saw belt
Adjust the setting using the setscrews so that the saw belt passes as close as possible through the casing of the saw arch. Once the adjustments have been completed, the securing screws must be retightened. Securing screws
Aligning the saw belt
Setscrews
Illustr.6-7: Saw arch
INFORMATION Before making the adjustment, change the saw belt. You cannot make the alignment with a warped saw belt.
© 2003
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 34
quantum
Maintenance
MASCHINEN
as required
Where ? Work-holder vice
Intervals / When ?
What ?
-
GERMANY
How ? Lubricate the spindle of the work-holder vice
Spindle
Unscrew the oil bleed screw at the bottom of the helical gear. To collect the oil, use a suitable vessel of sufficient capacity. Open the filler for better ventilation. Use viscous gear oil, e.g. Mobil 629 Helical gear
every year
Helical gear
Filler
Oil change
Illustr.6-8: Helical gear
INFORMATION
GB
© 2003
Let the metal belt saw run for a few minutes before beginning the oil change. This will heat the oil, making it flow more easily out of the outlet hole.
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 35
quantum MASCHINEN
Intervals / When ?
-
Maintenance
GERMANY
Where ?
What ?
How ? ATTENTION! This metal belt saw is designed to use saw belts of 2,362 x 19 x 0.9 mm. The use of other saw blades can cause inferior sawing results Place the saw arch in vertical position and close the shutoff tap on the support cylinder. Remove the red guard from the saw belt by loosening the two securing screws. Remove the saw belt brush by unscrewing the lockscrew. Remove the protective cover from the saw arch. Loosen the tension of the saw belt by turning the hand wheel anti-clockwise. “Adjusting the tension in the saw belt“ on page 32 Carefully remove the old saw belt. Fit the new saw blade by inserting it first into the saw belt guide.
after wear
Saw arch
Check the running direction and the toothing. “Direction of the saw teeth“ on page 19
Changing the saw belt
Place the saw belt on the two pulleys so that it is as close as possible to the casing of the saw arch. Tighten the saw belt. “Adjusting the tension in the saw belt“ on page 32. Run a check as described in
“Checking“ on page 19.
For fitting the components proceed in reverse order. Perform a run test.
“Aligning the saw belt“ on page 34
Fit the protective cover on the saw arch. Protective cover
Belt guide pulley
Saw arch casing
Saw belt
Illustr.6-9: Saw belt change
© 2003
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 36
quantum
Maintenance
MASCHINEN
Intervals / When ?
Where ?
What ?
-
GERMANY
How ? m The cooling pump is almost maintenance free.
Liquid cooling system
Replace the cooling agent regularly, depending on usage.
as required
Because cooling agents are used that leave residues, the cooling pump must be washed. Cooling pump
Cooling pump
Illustr.6-10: Cooling pump
6.3
Repair For any repair work, get assistance from an employee of Optimum Maschinen GmbH's technical service or send us the metal belt saw. If the repairs are carried out by qualified technical staff, they must follow the indications given in this manual. Optimum Maschinen GmbH does not take responsibility nor does it guarantee against damage and operating anomalies resulting from failure to observe this instruction manual. For repairs, only use faultless and suitable tools, original spare parts or parts from series expressly authorised by Optimum Maschinen GmbH.
GB
© 2003
• •
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 37
quantum MASCHINEN
6.4
-
Maintenance
GERMANY
Wiring diagram
© 2003
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 38
© 2003 GB
19 December 2005
Version 1.4
GERMANY
quantum -
Metal belt saw
MASCHINEN
S 181
Page 39
Illustr.6-11: Exploded view 1
Maintenance
Exploded view 1 6.5
GERMANY
Metal belt saw
-
quantum
S 181
Version 1.4
Maintenance
19 December 2005
© 2003
Page 40
Illustr.6-12: Exploded view 2
MASCHINEN
Exploded view 2 6.6
GB
quantum
Maintenance
MASCHINEN
GB
© 2003
6.6.1
-
GERMANY
Spare parts list - metal belt saw
Pos.
Name
Qty.
1
Chip tray
1
0328151
2
Lft. upright
1
0328154
2-1
Feet stand
1
2-2
Washer
2
1/4
2-3
Spring washer
2
1/4 5/16 x 11/2
2-4
Hexag. head screw
4
2-5
Handgrip
1
2-6
Hexag. head screw
4
Size
Code
5/16 x 11/2
2-7
Washer
4
5/16
2-8
Washer
4
5/16
2-9
Spring washer
4
5/16
2-10
Nut
4
5/16
3
Rt. upright
1
0328155
4
Side panel
1
0328156
5
Shelf
1
13
Hexag. head screw
8
5/16 x 3/4
14
Spring washer
8
5/16
15
Washer
8
5/16
16
Spring washer
8
5/16
17
Nut
8
5/16
18
Hexag. head screw
6
5/16 x 1/2
19
Nut
6
5/16
20
Cylinder
1
21
Allen screw
1
M10x40
22
Washer
1
3/8
23
Spring washer
1
3/8
24
Nut
1
M10
25
Hexag. head screw
2
3/8 x 1
26
Spring washer
2
3/8
27
Support rod
1
28
Hexag. head screw
1
29
Cylinder support
1
33
Washer
4
34
Wheel
4
35-1
Wheel axle
2
36
Split pin
2
38
Electric cord assembly
1
39
Work table
1
40
Hexag. head screw
5
5/16 x 1
41
Washer
5
5/16
19 December 2005
0328121
1/4 x 3/8
8"
0328144 0328109
0328138
Version 1.4
Pos.
Name
Qty.
Size
42
Spring washer
5
5/16
43
Nut
5
5/16
44
Filter
1
45
Hexag. head screw
2
3/16 x 3/8
46-1
Round head screw
1
3/16 x 1/2
47
Hand wheel
1
48
Set screw
1
5/16 x 3/8
49
Feather Key
1
5 x 20
50
Lead screw
1
51
Nut seat
1
52
ACME nut
1
53
Button
1
54
Retainer
1
55
Spring washer
1
M5
56
Round head screw
1
M5 x 8
57
Hexag. head screw
2
5/16 x 5/8
58
Spring washer
2
5/16
59
Support plate
1
60
Stop screw
1
61
Nut
1
5/16
62
Hexag. head screw
1
3/8 x 1
63
Nut
1
3/8
64
90° Position support
1
65
Nut
2
3/8 3/8
Code
0328107
0328118
66
Spring washer
2
67-1
End stop switch
1
67-2
Round Head screw
68-1
End stop switch plate
68-2
Round Head Screw
69
Round head screw
2
5/32 x 1
70
Hexag. head screw
2
3/8 x 1 1/2
71
Hexag. head screw
1
5/16 x 3/4
72
Butterfly screw
1
0328139
73
Stop support
1
0328126
74
Work stop rod
1
75N
Nut
2
1/2
76
Washer
2
1/1
77
Bearing busher (front)
1
78
Moulded rubber piece
1
79
Washer
2
3/32
80N
Shaft support
1
22 mm
81
Pivot arm
1
S 181
1
Metal belt saw
0328116 0328128
Page 41
quantum MASCHINEN Pos.
-
Maintenance
GERMANY
Name
Qty.
Size
84
Plate
1
120
85
Spring washer
2
121N
86
Hexag. head screw
2
122
Spring washer
4
3/8
87
Spring
1
123
Hexag. head screw
4
5/16 x 1 1/4
88
Lever for adjusting spring
1
123-1
Adjusting screw
2
1/4 x 3/8
124
Rear rolling pulley
1
125
Bearing bushing
1
126
Hexag. head screw
3
0328149
127
Saw belt
1
3357520
128
Rear saw cover
1
129
Pulley cover
1
130
Plum screw
2
131
Adjustment button
2
0328111
132
Rear saw belt guide
1
0328102
133
Guide bearing
2
134
Rear saw belt adj.
1
135
Bearing pin
2
136
Eccentric shaft assembly
2
136-1
Center shaft assembly
2
137
Nut
4
3/8 x 11/2 0328122
89
Spring bracket
1
90
Hexag. head screw
1
5/16 x 1
91
Nut
2
5/16
92
Spring washer
1
5/16
93
Nut
1
94
Front cover
1
95
Back cover
1
96
Vise thrust shaft
1
Pos.
Name
Qty.
Size
Oil seal
1
25.47.7.
Gear box
1
0328133
0328117
Spring washer
2
3/8
96-2
Washer
2
3/8
97
Hexag. head screw
1
3/8 x 1 1/2
98
Hexag. head screw
1
1/2 x 1 1/2 3/8
608 ZZ 0328104
98-1
Washer
98-2
Washer
99
Hexag. head screw
1
100
Scale
1
101
Hexag. head screw
1
1/4 x 11/2
138
Washer
2
5/16
102
Hose
1
1"
139
Spring washer
2
5/16
103-1
Pump
1
140
Hexag. soc. screw
1
5/16 x 1 1/8
141
Hd. screw
2
1/4 x 1/2
142
Vertical cutting plate (small)
1
143
Adjustable saw belt seat (front)
1
144
Hexag. head screw
2
145
Top carriage
1
146
Spring washer
2
3/8
147
Nut
2
3/8
148
Round-headed screw
2
1/4 x 1/2
149
Washer
2
1/4
1/2
103-2
Round Head Kopf
103-3
Coolant Pump Bracket
104
Hexag. head screw
4
107
Coolant tank
1
Code
5/16
96-1
1
Code
3/8 x 1 1/4
1/4 x 1/2
108
Fitting
1
109
Hose clamp
1
13 mm
110
Flexible tube
1
5/16
111
Saw arch
1
112N
Tapping screw
4
113
Vent plug
1
114N
Gear casing cover
1
115N
Gear casing gasket
1
116
Worm gear
117
Key
118
Ball bearing
3
6005
119
Hexag. soc. screw
2
3/8 x 1
119-1
Spring washer
1
3/8
119-2
Washer
1
3/8 x 35 x 4
0328152 6 x 20
3/8 x 24 UNF
0328119
0328108
3/8 x 1 1/4 0328140
150
Brush-holder
1
0328137
151
Hexag. head screw
1
5/16 x 2 1/2
0328148
1
0328124
152
Nut
1
5/16
2
0328120
153
Brush
1
154
Hexag. head screw
3
155 N
Magnetic switch
1
156
Nozzle
1
157
Setscrew
1
0328114 5/16 x 5/8
1/4 x 1/4
© 2003
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 42
quantum
Maintenance
MASCHINEN
Pos.
Name
Qty.
158
Nozzle support
159
Valve
160
Round-headed screw
2
161
Hexag. soc. screw
1
163
Adjustable bracket (front)
1
Name
Qty.
Size
1
199
Ball bearing
3
6003
1
200
Block plate
1
3/16 x 3/8
201
Oil seal
1
5/16 x 1 1/8
202
Bearing bushing
1
Saw belt protection
1
165
Hexag. head screw
4
166
Sliding guide plate
2
167
Setscrew
1
168
Hexag. head screw
2
169
Blade tension sliding block
1
170
Hexag. head screw
1
Code
GERMANY
Pos.
164
Size
-
0328101
Code
17.35.8.
203
Worm shaft
1
203-1
Key
1
5x5x50
0328125
204
Hexag. head screw
2
1/4 x 3/8
205
Washer
2
1/4
206
Support plate
1
207
Limit switch rack
1
208
Hexag. head screw
1
1/4 x 1/2
209
Nut
1
1/4
210
Washer
2
1/4
Spring washer
1
1/4
1/4 x 1/2
5/16 x 3/4 5/16 x 1 1/2
1/4 x 1/2
171
Sliding draw block
1
211
172
Bracket
1
212
Hexag. head screw
1
1/4 x 1/2
173
Bearing bushing rear
1
213
Nut
1
5/16
174
Ball bearing
2
214
Hexag. head screw
1
5/16 x 1 1/4
215
Washer
1
1/4
217
C-Ring
2
R47
Gear complete
1
6203 ZZ
175
Front rolling pulley
1
0328134
176
Washer
1
5/16
177
Hexag. head screw
1
5/16 x 3/4
178
Round-headed screw
4
1/4 x 1/2
179
Washer
4
1/4
180
Washer
1
3/8
181
saw belt adjustable handle
1
182
Vertical cutting plate
1
183
V-belt
1
184
Worm Pulley
1
3V-270 0328129
185
Motor Pulley
1
0328127
186
Setscrew
2
5/16 x 3/8
187
Hexag. head screw
2
1/4 x 1/2
188
Washer
2
1/4
189
Belt casing
1
190
Plum screw
1
191
Key
1
192
Motor
1
193
Hexag. head screw
4
194
Motor mount plate
1
195
Washer
4
5/16
196
Spring washer
4
5/16
197
Nut
4
5/16
198N
Worm shaft stopper
1
198-1
Set screw
1
0328131
5 mm 0328136 5/16 x 1
GB
© 2003
5/16x1/4
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 43
quantum MASCHINEN
-
Anomalies
GERMANY
7
Anomalies
7.1
Anomalies in the metal belt saw Anomaly
Cause / possible effects
Suggested solution
Saw motor overloading
•
Suction of motor cooling air hindered Motor not correctly fixed Power unit for saw belt not properly fixed
•
Check and clean
•
Requires technical service! Have the machine repaired in the workshop
• • • • •
•
Cooling agent tank empty Cooling agent tap closed Cooling agent tap blocked Cooling agent duct bent or blocked Air in the system, e.g. after re-filling Pump doesn't work
•
Fill Open Clean Check and clean Bleed by briefly withdrawing the pressure hose Start pump
The saw belt stops when sawing, but the saw motor operates
• •
Insufficient saw belt tension Tension in the V-belt
• •
Check saw belt Check tension of belt
Short life of saw belt
•
Quality of saw belt not suitable for this material An incorrect tooth spacing causes breakage of teeth (the broken tooth in the work piece blunts the other teeth) Missing cooling Cutting speed too high Feed too high
• •
Higher quality saw belt (choose bimetallic belt) Select correct tooth spacing
• • •
Use cooling system Reduce cutting speed Reduce feed
• •
Cooling agent feed not working
(Teeth blunted)
• • • • •
•
• • •
Breakage of teeth
•
Chip space in the saw belt full, tooth spacing incorrect
•
Use saw belt with a different tooth spacing or reduce feed
Breakage of the saw belt
•
Tension in the saw belt too high or too low Saw belt defective Saw belt guide adjusted incorrectly
•
Check tension of the saw belt
• •
Replace Adjust saw belt guide correctly
Distance between guide and workwork piece too high Saw belt blunt Saw tension too low Feed too high Cutting pressure too high Saw belt defective (irregular set) Saw blade guide badly set
• • • • • • •
Bring the guide as close as possible to the work piece Replace Tighten correctly Reduce Reduce Replace Readjust
Material does not rest on both rails of the work-holder vice Clamps of the work-holder vice not adjusted to 90º
•
Support material properly
•
Adjust clamps correctly
• •
Twisted cut (saw belt deviating)
• • • • • • •
Cut not rectangular, but parallel
• •
© 2003
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 44
quantum
Appendix
MASCHINEN
8
Appendix
8.1
Copyright
-
GERMANY
© 2003 This document is copyright. All derived rights are also reserved, especially those of translation, re-printing, use of figures, broadcast, reproduction by photo-mechanical or similar means and recording in data processing systems, whether partial or total. The company reserves the right to make technical alterations without prior notice.
Terminology/Glossary Item
Explanation
Work piece
•
Material to be sawed
Belt guide pulley
•
Pulley through which the saw belt passes in the saw arch
Saw arch
•
Casing with protective cover for the saw belt
Depth stop
• •
Position for multiple cuts Sawing stop
Hydraulic cylinder
• •
Hydraulic lowering cylinder Hydraulic feed
Feed regulation valve
•
Valve on the hydraulic cylinder
Protective cover for V-belt
•
Protective cover of the V-belts
Protective cover for saw arch
•
Cover on the rear of the saw arch
Belt guide bearings
• •
Rollers between which the saw belt passes and is guided Guide bearing
Saw belt guide
•
Belt guide bearings
Saw belt brush
• •
Device for scraping off impurities Saw belt cleaning brush
Clamp
•
Adjustable block on the work-holder vice
Work-holder vice
•
Clamping device for the work piece
Helical gear
•
Reduction gear from the drive motor to the pulley for V-belt
Drive motor
•
Motor
GB
© 2003
8.2
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 45
quantum MASCHINEN
8.3
-
Appendix
GERMANY
Product follow-up We have a follow-up service for our products which extends even after shipment.
We would be grateful if you could send us the following information • • •
Modified settings Experiences with the metal belt saw, which could be important to other users Recurring failures
Optimum Maschinen Germany GmbH Dr.-Robert-Pfleger-Str. 26 D-96103 Hallstadt, Germany Fax +49 951 - 96 555 - 99 E-Mail:
[email protected]
© 2003
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 46
quantum
Appendix
MASCHINEN
8.4
-
GERMANY
EC Declaration of Conformity The manufacturer / retailer:
Optimum Maschinen GmbH Dr.-Robert-Pfleger-Str. 26 D-96103 Hallstadt
hereby declares that the following product Type of machine:
Metal belt saw
Name of machine:
S 181
Relevant EU directives: Machinery Directive
98/37/EC, Annex II A 89/336/EEC
Low voltage directive
73/23/EEC
meets the provisions of the aforementioned directive, including any amendments valid at the time of this statement. In order to ensure conformity, the following harmonised standards in particular have been applied: EN 418: 01/1993
Safety of machinery - Emergency stop equipment, functional aspects - Principles for design.
EN 60034-1: 09/2000
Rotating electrical machines - Part 1: Ratings and operating characteristics.
EN 60034-9: 06/1998
Rotating electrical machines - Part 9: Noise limits.
EN 60204-1:11/1998
Safety of machinery - Electrical equipment of machines - Part 1: General requirements
EN 50081-2: 03/1994
Electromagnetic Compatibility -Generic Emission Standard - Part 2: Industrial environments.
EN 61000-3-3: 03/1996
Electromagnetic compatibility (EMC) - Part 3-3: Limit values - Limit value regarding power fluctuations and interruptions in the power supply network for equipment with an input current up to and including 16 A.
Kilian Stürmer (Managing director)
Thomas Collrep (Managing director)
GB
© 2003
Hallstadt, 19.12.2005
19 December 2005
Version 1.4
S 181
Metal belt saw
Page 47
quantum MASCHINEN
9
-
Index
GERMANY
Index
A
T
Accident report .............................................. 14 Assembly ....................................................... 17
Declaration of Conformity .............................. 47
Table of revolutions ....................................... 28 Technical data Cooling pump ......................................... 16 Cutting field ............................................ 15 Emissions ............................................... 16 General ................................................... 15 Operating material .................................. 16 Power connection ................................... 15 Speed of saw blade ................................ 16 Terminology/Glossary ................................... 45
E
U
EC Declaration of Conformity ........................ 47 Electrical system Safety ...................................................... 14 EMERGENCY button ...................................... 9 Emissions ...................................................... 16 Exploded view Metal belt saw ................................... 39, 40
User position ................................................... 9 User positions ................................................. 9
C Checking ....................................................... 19 Copyright ....................................................... 45 Cutting field ................................................... 15 Cutting speeds .............................................. 28
D
W Warning notes ................................................. 5 Wiring diagram .............................................. 38
H Hazards - Classification .......................................... 5 Hydraulic feed ............................................... 29
O Obligations Operator .................................................... 8 User .......................................................... 8 Operating material ......................................... 16
P Parts list ......................................................... 17 Pictograms ...................................................... 6 Power connection .......................................... 15 Proper use ....................................................... 6 Protection -Individual protection gear ...................... 12
Q Qualification of Personnel Safety ........................................................ 7 Qualification of personnel Safety ........................................................ 7
S
Metal belt saw
S 181
Version 1.4
19 December 2005
GB
Page 48
© 2003
Safety - devices ................................................... 9 - warnings ................................................. 5 -Devices .................................................... 9 during maintenance ................................ 13 during operation ...................................... 12 Spare parts list Metal belt saw ......................................... 41 Storage and packaging ................................. 17
