Cosen SH-700DM User manual

COSEN SAWS
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SH-700DM
Semi‐AutomaticSwivelHead
DoubleMiteringHorizontalBandsaw
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InstructionManual
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ThePinnacleofCuttingPerformance
CosenMechatronicsCo.,Ltd.

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NOTE:
Readthisinstructionmanualcarefullytofamiliarizeyourselfwiththeinstallation,operation
andmaintenanceofyourCOSENbandsawmachine.
Operatethemachinefollowingtheproceduresdescribedinthemanualtopreventpersonal
injuriesormachinedamage.
Keepthismanualhandyandrefertoitwheneveryouareuncertainofhowtoperformanyof
theprocedures.
Fortechnicalsupportorpartspurchase,pleasecontactyournearestCOSENrepresentativeor
ourservicecenter:
ForUS,Mexico,andCanada:
email:[email protected].
phone:+1‐704‐943‐1030
tollfree:+1‐877‐SAWING1
fax:+1‐704‐943‐1031
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ForTaiwanandothercountries:
email:[email protected]
phone:+886‐3‐5332143
fax:+886‐3‐5348324
ForEurope:
email:
[email protected]
phone:+31‐77‐7600280
fax:+31‐77‐7600288
ForChina:
email:[email protected]
phone:+86‐152‐50127815
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InstructionManual: SH‐700DM
Semi‐AutomaticSwivelHeadDoubleMiteringHorizontalBandsaw
Ver.42017/1/9
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©2013byCOSENMECHATRONICSCO.,LTD.
NopartofthispublicationmaybephotocopiedorotherwisereproducedwithoutthepriorwrittenpermissionofCOSEN.
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PrintedinTaiwan
FROMTHEMANUFACTURER
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ThankyouforyourpurchaseofCOSEN’sbandsawmachineandyourtrustinthe
COSENbrand.
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Weareexcitedtohaveyouasourvaluedcustomerandlookforwardasmuchasyou
dototheacceleratedproductivity,long‐lastingenduranceandsuperb
cost‐effectivenessthismachineisabouttobringtoyou.
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Toensureyouarefullyutilizingourmachineandbeingadvantagedineverypossible
way,pleasedotakeyourtimeandreadthroughthisinstructionmanual.
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Anycommentorsuggestioninmakingourservicebetter,pleasedonothesitateto
letusknow.Thankyouagain!

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Safety rules
Makesureyourworkareaisclearedofuninvitedpeopleandobstacleseverytimebeforeyoustart
operatingthemachine.
Neverwearglovesorlooseclothingwhenoperatingthemachine.Itmayleadtoseriousinjuryifthey
arecaughtintherunningmachine.Wraporcoverlonghair.
Useawater‐solublecuttingfluidonthismachine.Oil‐basedcuttingfluidsmayemitsmokeorcatch
fire,dependingonhowtheyareused.
Nevercutcarbonoranyothermaterialthatmayproduceanddisperseexplosivedust.Itispossible
thatsparksfrommotorsandothermachinepartswilligniteandexplodetheair‐bornedust.
Makesureanyuseoffireisprohibitedintheshopandinstallafireextinguisherorotherfirecontrol
devicenearthemachinewhencuttingtitanium,magnesium,oranyothermaterialthatproduces
flammablechips.Neverleavethemachineunattendedwhencuttingflammablematerials.
Neveradjustthewirebrushorremovechipswhilethesawbladeisstillrunning.Itisextremely
dangerousifhandsorclothingarecaughtbytherunningblade.
Nevertouchtherunningsawbladewithglovesornot.Itisdangerousifyourhands,clothingor
glovesarecaughtbytherunningblade.
Stopthesawbladebeforeyoucleanthemachine.Itisdangerousifhandsorclothingarecaughtby
therunningblade.
Neverstartthesawbladeunlesstheworkpiecehasbeenclampedfirmly.Iftheworkpieceisnot
securelyclamped,itwillbeforcedoutoftheviseduringcutting.
Takepreventivemeasureswhencuttingthinorshortpiecesfromtheworktokeepthemfrom
falling.Itisdangerousifthecutpiecesfall.
Userollertablesatthefrontandrearsidesofthemachinewhencuttinglongwork.Itisdangerousif
theworkpiecefallsoffthemachine.
Neversteporstandontherollertable.Yourfootmaysliportripontherollersandyouwillfall.
Turnofftheshopcircuitbreakerswitchbeforeperformingmaintenanceonthemachine.
Postasignindicatingthemachineisundermaintenance.
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able of Contents
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Section1–SafetyInformation1‐1
SafetyInstructions……………………………………………………………………………………………………… 1‐1
SafeguardDevices………………………………………………………………………………………………………. 1‐3
EmergencyStop…………………………………………………………………………………………………………. 1‐4
Illustration:EmergencyStop……………………………………………………………………………………… 1‐5
SafetyLabels………………………………………………………………………………………………………………. 1‐6
Illustration:SafetyLabels………………………………………………………………………………………….. 1‐7
HearingProtection……………………………………………………………………………………………………… 1‐8
CECompliance……………………………………………………………………………………………………………. 1‐8
RiskAssessment…………………………………………………………………………………………………………. 1‐8
Section2–GeneralInformation2‐1
Specifications……………………………………..………………………………………………………………………. 2‐2
MachinePartsIdentification………………………………………………………………………………………. 2‐3
FloorPlan…………………………………………………………………………………………………..………………. 2‐4
Section3–Moving&Installation3‐1
Location&Environment………………………………..…………………………………………………………… 3‐1
Unpacking&Inspecting……..………………………………………………………………………………………. 3‐2
Lifting…………………………………………..………………………………………………………………….…………. 3‐3
Illustration:LiftingPoints…………………………………………………………………….……………………. 3‐5
RemovingShippingBracket…………………………..……………………………………………….…………… 3‐6
Cleaning…………………………………………..…………………………………………………………….…………… 3‐6
Installing…………………………...………………………………………………………………………….……………. 3‐6
SupplyingHydraulicOil…………………………………………………………………….……………. 3‐6
SupplyingCoolant………..………………………………………………………………….…………….. 3‐7
ConnectingElectricPower……………………………………………………………….…………….. 3‐7
Leveling&Anchoring…………………………………………………………………….………………. 3‐8
InstallingRollerTable(Optional)………………………………………………….…………………. 3‐9
InstallingFireControlDevice………………………………………………….……………………… 3‐9
Relocating………………………...…………………………………………………………………….…………………. 3‐9
Section4–OperatingInstructions4‐1
SafetyPrecautions…………………..…………………..……………………………………….……………………. 4‐2
BeforeOperating…………………………..……………………………………………………………………………. 4‐3
ControlPanel……..……………………………………..………………………………………….……………………. 4‐4
ControlPanel………………….………………………………………………………………………..……. 4‐4
ControlButtons……………………………………………………………………………………….…….. 4‐5

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StandardAccessories………….………………………..……………………………………………….…………… 4‐7
OptionalAccessories…….…….………………………..…………………………………………….……………… 4‐9
Unrolling&InstallingtheBlade…………………………………………………………………….……………. 4‐11
AdjustingWireBrush………..……………………………………………………………………….………………. 4‐13
AdjustingMaterialDepthBar…………………………………………………………………….……………….. 4‐13
AdjustingSawArm………..……………………………………………………………………….…………………… 4‐14
AdjustingCoolantFlow………..………..…………………………………………………………………..………. 4‐14
AdjustingBladeSpeed………..………..……………………………………………………………………………. 4‐15
Breaking‐IntheBlade………..………..…………………………………………………………………..…………. 4‐15
Test‐RunningtheMachine………..………………..…..…………………………………………………………. 4‐15
CuttingOperation………..………..……………………………………………..……………………………………. 4‐16
UsingTopClampforBundleCutting………..……….………………………………………………………… 4‐17
TerminatingaCuttingOperation………..………..…………………………………….………………………. 4‐17
Section5–ElectricalSystem5‐1
ElectricalCircuitDiagrams……….…………………..…………………………………………………………….. 5‐1
Section6–HydraulicSystem6‐1
HydraulicDiagrams……….…………………..……………………………………………………………….………. 6‐1
Section7–BandsawCutting:APracticalGuide7‐1
Introduction……………………….…….…………………..……………………………………………………………. 7‐1
SawBladeSelection………………….…………………..…………………………………………………………… 7‐1
SomeSawingPractices…………….…………………..………………………………………….………………… 7‐4
SawPitchSelection……………………………………………………………………….……………….. 7‐4
MaterialSizeandSawPitch………………………………………………….….……………………. 7‐4
Section8–Maintenance&Service8‐1
Introduction……………………….…….…………………..……………………………………………………………. 8‐1
BasicMaintenance………………….…………………..…………………………………………….………………. 8‐1
MaintenanceSchedule…………….…………………..……………………………………………………………. 8‐2
BeforeBeginningaDay’sWork………………………………………………………………………. 8‐2
AfterEndingaDay’sWork…………………………………………………….……………………….. 8‐2
EveryMonth………………………………………………………………………….………………………. 8‐2
EveryThreeMonths………………..…………………………………………….………………………. 8‐2
EverySixMonths……………….………………………………………………….………………………. 8‐3
StorageConditions…………………………....………..…………………………………………………………….. 8‐3
TerminatingtheUseofMachine……..…………..…………………………………………………………….. 8‐3
OilRecommendationforMaintenance………………………………………………………………………. 8‐4

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Section9–Troubleshooting9‐1
Introduction……………………….…….…………………..……………………………………………………………. 9‐1
Precautions………………….…………………..……………………………………………………………………..... 9‐2
GeneralTroubles&Solutions………………………..……………………………………………………………. 9‐2
MinorTroubles&Solutions………………………..………………………………………………..……………. 9‐3
MotorTroubles&Solutions………………………..…………………………………………………..…………. 9‐3
BladeTroubles&Solutions………………………..……………………………………………………………….. 9‐4
SawingProblems&Solutions………………………..…………………………………………………………… 9‐5
Re‐AdjustingtheRollerTable………………………..……………………………………………………………. 9‐6
Section10–Parts10‐1
SparePartsRecommendations…………………..………………………………………………………………. 10‐1
PartList…………………..…………………………………………………………………………………………………. 10‐1
Section11–Warranty11‐1
Warranty…………………..……………………………………………………………………………………………….. 11‐1
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1‐1
Section1
SAFETY
INFORMATION
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SAFETYINSTRUCTIONS
SAFEGUARDDEVICES
EMERGENCYSTOP
SAFETYLABELS
HEARINGPROTECTION
CECOMPLIANCE
RISKASSESSMENT
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Safetyisacombinationofawell‐designedmachine,operator’sknowledgeaboutthemachineand
alertnessatalltimes.COSEN’sbandmachinehasincorporatedmanysafetymeasuresduringthe
designprocessandusedprotectivedevicestopreventpersonalinjuriesandpotentialrisks.Warning
labelsalsoserveasaremindertotheoperator.

Throughoutthismanual,youwillalsoseevarioussafety‐relatedsymbolsindicatingimportant
informationthatyoushouldtakenoteofpriortouseofthemachineorpartofitsfunctions.These
importantsafetyinstructionsdonotcoverallpossiblesituationsthatmightoccur.Itisyour
responsibilitytotakecautionandfollowproceduresstatedinthismanualwheninstalling,
maintainingandoperatingyourmachine.Cosenwillnotbeliablefordamagesresultingfrom
improperuse.


SAFETYINSTRUCTIONS
Whattheiconsandsignsinthisusermanualmean:

ThisiconmarksDANGER;hazardsorunsafepracticesthatmayresultinsevere
personalinjuryordeath.

ThisiconmarksWARNING;hazardsorunsafepracticesthatmayresultin
personalinjuryordamagetothemachine.

ThisiconmarksCAUTION;informationthatshouldbereadbeforeusetoprevent
damagetothemachine.
Supplementaryinformationtotheproceduresdescribedinthismanual.
Callyourlocalagentorourservicecenterforhelp.

1‐2
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
Thismanualhasimportantsafety
information.Readthroughitcarefully
beforeoperatingthismachinetoprevent
personalinjuryormachinedamage.Learn
theoperation,limitationandthespecific
potentialhazardspeculiartothisband
saw.

Donotoperatethismachineunlessitis
completelyassembled.

Makesurethepowerswitchisoffbefore
plugginginpowercord.

Disconnectthepowercordbeforemaking
adjustment,maintenanceorblade
changes.

Keepallguardsandshieldsinplacebefore
installingorstartingupthemachine.

Wearproperapparelduringoperation
andwhenservicingthemachine.
Keepunauthorizedpersonnelaway.

Donotreachoverorstandonanypartof
themachine.

Neverholdthematerialbyhandfor
cutting.Alwaysusetheviseandmake
surethematerialisclampedsecurely
beforecutting.

Itisdangeroustooperatethemachine
whenthefloorisslippery.Keepthefloor
cleananddry.Checkforice,moisture,or
greasebeforeentering.

Donotusethemachinetocutexplosive
materialorhighpressurevesselsasitwill
generategreatamountofheatduringthe
sawingprocessandmayignitean
explosion.

Keeptheworkenvironmentsafe.Donot
usebandsawinadamporwetlocation.

Neveroperatewhileundertheinfluence
ofdrugs,alcoholormedication.

Allusersmustreaditbeforeperformingany
activityonthemachine,suchasreplacing
thesawbandordoingregularmaintenance.
Somepersonalprotectiveequipmentis
requiredforthesafeuseofthemachine,e.g.
protectiongoggles.
Keepbladeprotectioncoverandwheel
coversinplaceandinworkingorder.
Userecommendedaccessories.Improper
accessoriesmaybehazardous.
Keepyourworkareawellilluminatedat
minimum500lumen.
Keepyourworkareaclean.Clutteredand
slipperyfloorsinviteaccidents.
Removeadjustingkeys,wrenchesorany
loosepartsoritemsfromthemachine
beforeturningonpower.
Checkfordamagedparts.Beforecontinuing
usingthemachine,thedamagedpartshould
becheckedandreplaced.
Movingpartsshouldbekeptinproper
alignmentandconnectionwiththemachine.
Checkforbreakage,mountingandanyother
conditionsthatmayaffectitsoperation.Any
damagedpartorguardshouldbeproperly
repairedorreplaced.
Whenaworkpieceistoolongorheavy,
makesureitissupportedwitharollertable
(recommended).
Alwaysremembertoswitchoffthemachine
whentheworkiscompleted.
Useasharpsawbladeandkeepthemachine
initsbestandsafestperformanceby
followingaperiodicalmaintenanceschedule.
Donotforcethebandsawbeyondits
intendeduse.Itissafertooperatewiththe
cuttingrateforwhichitwasdesigned.


1‐3
SAFEGUARDDEVICES
Thesafeguarddevicesincorporatedinthismachineincludethefollowingtwomainparts:
1. Protectioncovers&guards
2. Safety‐relatedswitches

ProtectionCovers&Guards
1. Idlewheelhousingcover
2. Drivewheelhousingcover
3. Gearreducercover
4. Wirebrushbeltcover
5. Bladeguardcover(left&right)

Theprotectiondevicesshouldalwaysbemountedonthemachinewheneverthemachineis
running.
Donotremoveanyofthesesafeguarddevicesunderanycircumstancesexceptwhenservicing
themachine.Evenskilledservicetechniciansshouldstilltakecautionswhenperformingrepairs
orserviceonthemachinewithanyoftheseprotectorsremoved.Itistheresponsibilityofthe
usertomakesurealltheseelementsarenotlostanddamaged.
Takenoteofthefollowingmainmovingpartsonthemachinepriortoandduringmachine
operation:
Sawbowassembly
Driveandidlewheels
Bladeguidearm
Sawbladeguiderollers
Quickapproachdevice
Wirebrush
Chipconveyor(optional)
Workpiececlampingvises
Shuttlevisesandworkbedrollers
Topclamps(optional)
Gearreducer









1‐4
SafetyRelatedSwitches
Toprotecttheoperator,thefollowingsafetyrelatedswitchesonthemachineareactuatedwhenthe
machineisinoperation.

WheelmotiondetectorThisisaproximitysensorusedtodetectthemotion
ofthedrivewheel.Oncethesawbladeisbrokenor
assoonasitstartsslipping,thesensorwilldetect
andstopthedrivewheelandthemachine.
PowerswitchLocatedonthecoverofelectricalcabinet,thepower
switchcontrolsthemainpowerofthemachine.Up
toyourcompany’sinternalrules,thispowerswitch
canbelockedwithapadlockoraluggagelockto
protecttheoperatorandthemachine.
EmergencystopbuttonLocatedonthecontrolpanel,thebuttonwhen
pressedwillstopthemachinecompletely.
ViseclampswitchThisswitchassuresfirmclampingoftheworkpiece.If
theworkpieceisnotclampedproperly,thesaw
bladeisnotallowedtorun.
Wheelcoverinterlockswitches
(CEmodelonly)
Locatedonthetwowheelhousings,theseswitches
areusedtoassurethatthemachinewillstop
wheneverthewheelcoversareopen.Thisdeviceis
toprotectusersfrombeingcutbytherunningsaw
blades.

Amongallthesesafetyswitches,someofthemareusedtoprotecttheusersandsomeofthemare
usedtopreventdamagetosawblades,theworkpieceandthemachineitself,etc.Wehavetaken
everyprecautiontopreventinjuryordamageandtoprovidesafeandeconomicaloperationofthe
machine.


EMERGENCYSTOP
Designedtobeeasilyaccessible,theemergencystopbuttonislocatedontheleftbottomcorneron
thecontrolpanelandismadeinredcolorandrubbermaterial.ForCEmodels,supplementary
emergencystopbuttonmaybeavailableatotherarea(s)ofthemachinedependingonmachinetype.
PleaserefertoIllustration:EmergencyStop.
Whenyoupressthebutton,themachinewillimmediatelycometoafullstoptoavoidinjuryor
damagewhenanaccidentoccurs.Thebuttonwillbelockedwhenyoupressit.Tounlockit,pullit
upward.
Youshouldpressitimmediatelywithoutanyhesitationwhenobserving:
Anemergencysituationthatwouldcauseanyinjuryordamage
Anabnormalsituationorproblemsuchasfire,smoke,abnormalnoiseandetc.

1‐5
Illustration:EmergencyStop








EmergencyStopButton

1‐6
SAFETYLABELS
Pleasereadthroughandunderstandthesesafetylabelsbeforeoperatingthemachine.Referto
Illustration:SafetyLabels.

LabelMeaningLabelMeaning

ImpactHazard

WEARSAFETYSHOES.Do
notapproachdroppingarea
duringoperation.
ReadOperator’sManual

Thismanualhasimportantsafety
information.Readthroughit
carefullybeforeoperatingthis
machinetopreventpersonalinjury
ormachinedamage.

KeepUnauthorized
PersonnelAway


Donotstep.

Donotstandonthemachineoron
theaccessories!

DANGER:RunningBlade

Bladerunsthroughthis
area.Keepyourhandsaway
fromarunningbladeto
avoidsevereinjury.The
arrowindicatesdirectionof
theblade.

CuttingHazard

KEEPCOVERCLOSED/KEEPHAND
OFFwhilethebladeisrunning.
Turnpoweroffbeforeopening
cover.Failuretofollowthewarning
canresultinsevereinjury.

HazardousVoltage

TURNPOWEROFFbefore
servicing.Failureto
followingthewarningcan
resultinsevereinjury.

BurnHazard/HotSurface

HandCrush/Forcefrom
Above

Crushhazardbyvise

LooseHandHazard

KEEPHANDOFF.Donot
touchchipconveyor.Failure
tofollowthewarningcan
resultinsevereinjury.

PinchPoint/HandEntanglement



1‐7
Illustration:SafetyLabels





1‐8
HEARINGPROTECTION
Alwaysuseearprotection!
Whenyourmachineisrunning,noisegeneratedbythemachinemaycomefromthefollowing:
Sawbladeduringcuttingormaterialfeedmechanism
Wirebrushunit
Chipconveyorunit
Speedreducer
Hydraulicmotor/pump
Belttransmissionsvariablespeedmotors
Blademotor
Coolantpump
Drivewheel
Partsnotassembledtightlycausingmechanicalvibration

Ourproductspassnoisetestinglessthan78dBA.Noiselevelvaryaccordingtoworkingconditions
andwerecommendearplugsorotherhearingprotectionatalltime.Ifyourmachineproducesan
undesirablenoisewhileitisrunning,youshould:
1. Makesureallmaintenancetaskshavebeenperformedfollowingtheprescribedmaintenance
schedule(RefertoSection8).
2. Ifmaintenancedoesnotseemtosolvetheproblem,followthetroubleshootingprocedures
underSection9.


CECOMPLIANCE
Cosen’sCEmodelisdesignedtosatisfyregulationsoftheCouncilDirectiveontheapproximationof
thelawsoftheMemberStatesrelatingtomachinery(2006/42/EC)‐AnnexIEssentialhealthand
safetyrequirementsrelatingtothedesignandconstructionofmachinery.


RISKASSESSMENT
Riskassessmentgenerallytakesaccountofintendeduseandforeseeablemisuse,includingprocess
controlandmaintenancerequirements.Wemadeeveryefforttoavoidanypersonalinjuryor
equipmentdamageduringthemachinedesignstage.However,theoperator(orotherpeople)still
needstotakeprecautionswhenhandlinganypartofthemachinethatisunfamiliarandanywhereon
themachinethathaspotentialhazards(e.g.theelectricalcontrolbox).




2‐1
Section2
GENERAL
INFORMATION

SPECIFICATION
MACHINEPARTSIDENTIFICATION
FLOORPLAN


ThisbandsawmachineisdesignedbyCosen’sR&Dengineerstoprovideyouthefollowingfeatures
andadvantages:
Safety
Thismachineisdesignedtofullyprotecttheoperatorfromitsmovingpartsduringcutting
operation.
Themachineandeachcompomenthaspassedstricttesting(CouncilDirectiveonthe
approximationofthelawsoftheMemberStatesrelatingtoMachinery).
Themachinewillshutoffautomaticallywhenthesawbladeisbroken,protectingboththe
operatorandthemachine.
Convenience&High‐Performance
Themachineisdesignedinthewaythattheoperationandadjustmentcanbeeasily
performed.
Themachinewillstopautomaticallywhenoutofstock.
Dualvalvesystemisdesignedtoachieveoptimalcuttingperformancewiththesimple
settingoffeedrateandperspectivecuttingpressurefordifferentmaterial.
Durability
Theintendedlife‐spanofthemachineiscountedbasedonregulardailyoperation.Itis
calculatedwiththelifeexpectancyof10yearsundernormaloperatingconditionandexact
attentiontothemaintenanceschedule.
8hours×5days×52weeks×10years＝20,800hours



2‐2
SPECIFICATION
ModelSH‐700DM
Semi‐AutomaticSwivelHeadDoubleMiteringHorizontalBandsaw
Capacity
Angle0° ± 45°+60°
Round 450 mm
(17.7”)
450 mm
(17.7”)
300mm
(11.8”)
Rectangular(HxW)450x700 mm
(17.7”x27.5”)
450x450 mm
(17.7”x17.7”)
300x450mm
(11.8”x17.7”)
BundleCutting W:710mm(28”)
H:455mm(17.9”)

SawBlade
Speed20 ~100m/min(66~328
f
pm)
Size5,800 x41 x1.3 mm(228” x1.6” x0.05”)
TensionHydraulicwithautomaticbladebreakagedetection
GuideInterchangeabletungstencarbide
CleaningSteelwirebrushwithflexibledriveshaftdrivenbymainmotor
Motor
Output
SawBlade7.5HP(5.6 kW)
Hydraulic1HP(0.75 kW)
CoolantPump1/8 HP(0.1kW)
Tank
Capacity
Hydraulic45 L(11.7 gal)
Coolant120 L(31.2 gal)
WorkbedHeight750mm(29.5”)
Weight
Net2,100kg(4,620lb)
Gross2,400kg(5,280lb)
FloorSpace(LxWxH)2,852 x1,945.5 x1,740 mm(112.3” x76.6”x68.5”)

2‐3
MACHINEPARTSIDENTIFICATION
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2‐4
FLOORPLAN
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Machinetopview