Dong Jin DCS - Series Quick start guide

HIGH SPEED CIRCULAR SAWING MACHINE
ISO9001/CE
SINCE1980
OPERATIONAL
M A N U A L
DCS-100H
DCS-125H
Thank you for purchasing
Dong Jin’s High Speed Circular
Sawing Machine DCS- series.
In order to use DCS- series
more efficiently, please read
this manual before operation.
ADDRESS
:
115BL 4LT NAMDONG Industrial complex, 685-3
Gojan-dong, Namdong-gu, Incheon, Korea
T E L
:
82-32-813-3041~4
F A X
:
82-32-672-0111
W E B
:
www.djmc.co.kr
E - m a i l
:
[email protected]

2
Please read the safety instruction carefully!
Before installation, operation and maintenance of the
machine, please read the next page Description of
Safety Precautions and Warning Signs carefully.
You should not try to install or operate this machine
until you have read this manual carefully and
understood its whole content. Otherwise, injuries and
damages might be caused by so doing.
Operators have to endure trainings of safety and
machine operations. After certified and authorized by
the employer, they can thus be allowed to operate the
machine.
If machine is treated improperly or safety regulations
are ignored, injuries and damages will be caused by so
doing.
Please contact us, once questions regarding this
manual or safety regulations arise.
This manual is deemed as an important document
attached to this machine. Please hand it over to the next
owner when the machine’s ownership is changed or
transferred.

3
This warning symbolized figure means Warning, no matter
when it appears in this manual or machine’s labels you must
take all the necessary of safety precautions.
They indicate danger of injury or death!!
This warning symbolizes figure means High Voltage Electrical
Facilities, no matter when they appear in this manual or
machine’s labels. You must take all the necessary of safety
precautions.
They indicate electrical shock of injuries or death!!!
Definition of Warning Signs
DANGER
The sign of “DANGER” in this manual or on the machine’s labels means loss of
life, severe personal injury or substantial property damage WILL entail if proper
safety precautions are not taken.
WARNING
The sign of “WARNING” in this manual or on the machine’s labels means loss
of life, severe personal injury or substantial property damage CAN entail if
proper safety precautions are not taken.
CAUTION
The sign of “CAUTION” in this manual or on the machine’s labels means minor
injury or property damage CAN entail proper precautions are not taken.
DANGER
Children and irrelevant operators must be prevented from accessing or
approaching the machine and strictly prohibited to touch any switch and knob.
DANGER AND WARNING
This manual should be placed in an obvious and accessible location where
people everyone is informed. The correct location and usage of “EMERGENCY”
button should be informed to everyone. Once hazardous condition happens,
operators on the site have to press “EMERGENCY” button to shut off the
machine.

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CONTENTS
1. Introduction
(1) Introduction ················································································· 6
(2) Specification ················································································ 7
(3) Part Name ···················································································· 8
2. Layout Drawing ·············································································· 9
3. Installation and Moving
(1) Installation of the machine ·························································· 10
(2) Transportation ············································································ 11
(3) Cleaning before operation ···························································· 12
(4) Coolant ······················································································ 12
(5) Power Source Facility ·································································· 13
4. The description of Control box ······················································ 14
5. Operation
(1) The adjustment of cutting stroke ·················································· 17
(2) The adjustment of vise stroke ······················································ 18
(3) Angular Cut ················································································ 19
(4) Fixed Vise Jaw ············································································ 20
(5) Stopper block ············································································· 20
(6) Saw Blade ··················································································· 21
(7) Vise Pressure Adjustment ···························································· 22
(8) Timer Adjustment ······································································· 23
(9) Saw Head Speed Control ······························································ 24

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6. Cutting Procedure ········································································ 25
7. Hydraulic System
(1) Hydraulic Circuit ········································································· 26
(2) Parts List ···················································································· 27
8. Electric System
(1) Electric Circuit ············································································ 28
(2) Part List ····················································································· 30
9. Maintenance
(1) Chip Scrapper ············································································· 32
(2) Chip Box ···················································································· 32
(3) Coolant Tank ·············································································· 32
(4) Assembly DWG. ·········································································· 33
①Stand Assembly ············································································ 33
②Table Assembly ············································································· 35
③Column Assembly ·········································································· 37
④Coolant & Blade Cover Assembly ······················································· 39
⑤Moving Vise Assembly ···································································· 41
⑥Gear Box Assembly ········································································ 43

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1. Introduction
(1) Introduction
WARNING
Any modification and change in usage of the machine is highly
prohibited for unexpected damage or hazard may occur.
Since the Saw Head of the machine cuts down smoothly the material
through the guide on the vertical column, the surface of material is very
clean and has almost no burr. This machine is very efficient for the precise
cutting.
The gear box consists of several “Carburizing Heat-Treatment”Helical
Gears, which are very durable. There is almost no noise and no vibration.
High drive-efficiency makes it possible to perform a powerful and fast
cutting.
Specially designed vise structure brings it to perform a powerful clamp
capacity. Knurling process and a high frequency heat treatment of vise
surface help the material to stick to the vise well. The support vises can be
adjustable depending on the length of material and they can move freely
according to operator’s preference.
The Sawing Head can be adjusted from left 45° to right 40° in order to
work the angular cutting.
The chip of cut-material on the saw blade can be rejected by chip ejector.
The cleaning of coolant tank is very easy.
You can keep the tools and blade in the front drawer inside of stand.

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(2) Specification
M O D E L
DCS-100H
DCS-125H
C U T T I N G
C A P A C I T Y
R O U N D
9080mm
4590mm
90125mm
45110mm
S Q U R E
9090x90mm
4580x80mm
90116x116mm
45108x108mm
RECTANGULAR
90140x75mm
4590x75mm
90170x100mm
45130x90mm
S A W H E A D
S P I N D L E
H S S S A W
B L A D E
300mmx40mmx2.5t
360mmx40mmx3t
M O T O R
1.5kW•2/4P•220V/380V•3
R P M
50Hz22/44
60Hz27/52
50Hz19/38
60Hz23/46
C H I P S C R A P P E R
URETHAN ROLLER
S A W H E A D M O V E M E N T
HYDRAULIC AUTOMATIC
M A I N V I S E
HORIZONTAL TYPE(HYDRAULIC)
C U T F E E D I N G S P E E D
3~300mm/min
H Y D R A UL I C
D E V I C E
PUMP MOTOR
0.75kW
W O R K I N G
P R E S S U R E
30kgf/㎠
O I L T A N K
V O L U M E
45ℓ
C O O L A N T
C O O L A N T
P U M P
60Wx4Px220Vx3
C O O L A N T
V O L U M E
14ℓ
APPEARANCE
S I Z E
(LxWxH)
1045x1135x1610mm
1045x1150x1700mm
W E I G H T
550kg
607kg
A C C E S S O R I E S
SPANNER: 24mm, 22mm, 19mm, 17mm
WRENCH: 1set
CONSENT: 1EA

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(3) Part Name
Fig.1
1
C Y L I N D E R
10
B L A D E C O V E R
2
M O T O R
11
S U P P O R T V I S E
3
C O N T R O L B O X
12
MAIN VISE CYLINDER
4
C U T T I N G S T R O K E
A D J U S T D E V I C E
13
H A N D L E
5
G E A R B O X
14
M A I N V I S E
6
R O U N D T A B L E
L O C K S C R E W
15
R O U N D T A B L E
7
SPEED CONTROL VALVE
16
C O L U M N
8
S T A N D
17
T A B L E
9
B E L T C O V E R
18
F I X E D V I S E

9
2. Layout Drawing
Fig.2

10
3. Installation and Moving
(1) Installation of the Machine
CAUTION
When you install the machine, please don’t give a severe hit or
impact to its main body. Please be careful not to break the gauges,
sensors and other fragile important parts on the machine.
The location of installation should be safe from vibration and other
influence of machines. Also its floor should be flat and strong enough to
endure the weight of machine.

11
(2) Transportation
WARNING
When transport and install machine, please be aware of that there is
no worker near the machine. We strongly recommend the expert to
use the crane and lift carrier for carry it.
When transporting the machine, please use the lift carrier or crane. For
lift carrier, the two legs of lift carrier should be placed the below of the
stand in order to carry safely. When you carry the machine with a lift carrier,
you should take into consideration of the center of gravity to prohibit the
machine from dropping out of the lift carrier. When you use crane, use four
(4) M12 hexagon bolts on the machine and over 12mm wire.(Fig.3)
The weight of DCS 100H is 550kg.
The weight of DCS 125H is 607kg.
Fig.3

12
(3) Cleaning Before Operation
WARNING
In order to remove the rust inhibitor, do not use the metal scrap. This
can bring the damage on the surface of machine; therefore it may
drop the precise of machine. Also do not clean the surface of machine
with toluene or thinner. It can remove the paint of surface.
When we ship the machine, we coat the rust inhibitor in order to prevent
the rust. Before operation, please remove the rust inhibitor thoroughly. If
not, it can affect the machine operation.
Please clean the sliding parts with kerosene or clean benzene.
(4) Coolant
WARNING
Please put the coolant before operation. If not, it brings damage the
coolant pump motor.
If necessary, please mix the coolant and water properly and put it into the
coolant tank. The volume of tank is 14 liter and be careful not to excess the
maximum limit of gauge when you put the coolant.

13
(5) Power Source Facility
DANGER
Without plug and outlet, you can connect the line directly to R.S.T. 3
phases line. In this case, the skilled electric engineer must connect. If
not, you may hurt or die by the electricity shock.
Please check the using voltage supply is appropriate with the machine’s 3
phases voltage. The voltage is written on the Power Switch of the control
panel.
The power can be connected under the condition that the volume of
breaker of factory should be more than 20A. Please connect power line over
2.0mm 2 with 4 core wire with tunnel of breaker.
♦Please connect ground wire before connecting power line.
♦Please wear the safety glove and be off the power before connecting
power line.
♦When operating the hydraulic pump motor, you must check if the
direction of motor rotation is as same as arrow direction of the cover of
hydraulic pump, if the direction isn’t same, the pump can be damaged
only after 10 seconds movement. If the direction is not same, please
exchange the 2 wires out of 3 wires of motor.

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4. The description of Control box
Fig.4
◈Power On
When you put on or off the power, please select the switches.(left: on,
right: off) When the lamp of select switch is not on, please check the
breaker in the control panel.
◈Control On
In order to operate the machine, you must push this S/W after turning
“power”to on. After pushing emergency S/W, you must push this switch
after release the emergency S/W and return to the initial point.
◈Manual/Auto
You can select the operation mode with this switch.(Manual/Auto)

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◈Saw Blade(Low/Stop/High)
It is Cam Switch. You can adjust the rotation speed of blade by selecting
the stage; Low, Stop, High.
WARNING
If the cam switch is on “Stop”point and put the operation mode on
“Auto”mode, the saw blade can be broken.
◈Vise Open/Close
Select the switch in order to open or close the vise.
WARNING
Vise Open/Close switch can only work under manual operation mode.
If you want to change Auto mode, please select Open position.
◈Emergency
In case of there is dangerous and emergency, please push this button. If
you push this button, the machine stops operation.
♦In order to restart, release the Emergency s/w first and check the
Manual/Auto S/W. If the mode s/w is Manual Mode, return to the initial
point with vise select s/w and saw head s/w. Then push the Control On
s/w. If the mode s/w is Auto Mode, change the mode s/w into Manual
and push the Control On S/W.

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◈Auto Start
One cycle auto operation
The procedure is as follow
①Vise Close
②Saw Rotation, Saw Head Down
③Saw Head Up and Stop, Saw Stop
④Vise Open
◈Saw Up/Down
In the manual mode, you can raise or down the saw head by selecting
this switch.
♦Before auto feed cutting, make it sure to set the appropriate saw head’s
stroke upper limit and lower limit with this switch depending on the
material thickness.

17
5. Operation
(1) The adjustment of Cutting stroke
Fig.5
①Select “Manual” mode on the control panel.
②With Saw Head Up/Down set the cutting stroke by raising the saw head.
◈Upper Limit Adjustment
Fix upper adjust dog to the height that there is no interference of
material.
◈Lower Limit Adjustment
Please down the Saw Head until the point of finishing cutting and stop
the saw head. At that point, fix the lower adjust dog to the limit switch.
WARNING
Please check upper limit switch is touched. If not, the automatic
operation is not working.

18
(2) The adjustment of vise stroke
Fig.6
Turn vise handle up to less than 10mm between material and vise and fix
it. Generally, around 5mm is the best distance between material and vise.

19
(3) Angular Cut
In order to work angular cutting, first loosen lock screw, located front
sides. Then turn the column right or left with position set handle. The round
table moves with column.(There is angular stopper on the left 45° point)
When you decide the point, tighten the lock screw.(Fig.7)
Fig.7
DANGER
In case of angular cutting, change the point of fixed vise jaw and
support vise in order to avoid saw blade’s interference.

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(4) Fixed Vise Jaws
①DCS-100H
Please use fixed vise jaws when you want to cut material less than
Ø90mm.
If you want to cut Ø90 ~Ø100mm, please remove the fixed vise jaws and
operate. In case of angular cutting, please move the fixed vise jaws left or
right to avoid the saw blade’s interference.
②DCS-125H
Please use fixed vise jaws when you want to cut material less than
Ø110mm.
If you want to cut Ø110~Ø125mm, please remove the fixed vise jaws and
operate. In case of angular cutting, please move the fixed vise jaws left or
right to avoid the saw blade’s interference.
(5) Stopper block
Stopper block moves front and back. You should set the material to the
stopper and cut.(Fig.8) The maximum length of stopper is 500mm.
Fig.8