Hafco Metalmaster ALU-350A User manual

ALUMINIUM SAW
OPERATION MANUAL
Edition No :AS-350-1
Date of Issue :11/2019
Model.
ALU-350A
Order Code S851
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NOTE:
In order to see the type and model of the machine, please see the
specication plate. Usually found on the back of the machine. See
example (Fig.1)
Fig.1
ALUMINIUM SAW
MACHINE
ALU-350A
MODEL NO.
SERIAL NO.
DATE OF MANF.
NOTE:
This manual is only for your reference. Owing to the continuous improvement of the HAFCO
METALMASTER machines, changes may be made at any time without obligation or notice.
Please ensure the local voltage is the same as listed on the specication plate before
operating this electric machine.
DistributeD by
www.machineryhouse.co.nz
MACHINE DETAILS
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C O N T E N T S:
1. GENERAL MACHINE INFORMATION
1.1 Specications................................................................ 4
1.2 Identication................................................................. 5
2. IMPORTANT INFORMATION
2.1 General Metalworking Safe Practices.................. 6
2.2 Mitre Saw Safety.......................................................... 9
2.3 Site Preperation........................................................... 10
2.4 Shipping Contents...................................................... 10
3. INSTALLATION
3.1 Assembly........................................................................ 11
3.2 Basic Controls............................................................... 11
3.3 Electrical Installation.................................................. 12
3.4 Full Load Current Rating........................................... 12
3.5 Compressed Air............................................................ 13
3.6 Pneumatic Vice Clamps............................................. 13
3.7 Oil Mist Coolant........................................................... 13
4. OPERATION
4.1 Setting and Adjustment........................................... 14
4.2 Cutting Operation....................................................... 16
5. MAINTENANCE
5.1 Lubrication Schedule................................................. 17
5.2 Troubleshooting.......................................................... 17
5.3 Replacing The Blade................................................... 19
Spare Parts............................................................................. 20
Risk Assessment Sheets.................................................... 28
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Order Code S851
Model ALU-350A
Cutting Head Action (Auto-Manual) Auto & Manual
Operation Type Swivel - Dual Mitre &
Compound Left
Round Capacity @ 90º / 45º (mm) 100 / 100
Square Capacity @ 90º / 45º (mm) 100 / 100
Rectangle Capacity @ 90º / 45º (mm) 100 x 195 / 100 x 135
Compound Rectangle Capacity @ 45º x 45º (mm) 135 x 35
Compound Square Capacity @ 45º x 45º (mm) 70 x 70
Blade Size (D x B x T) (mm) 350 x 30 x 3
Number of Teeth (No.) 120
Vice Clamping Fixture Pneumatic
Coolant System Spray Mist
Table Working Height (with Stand) (mm) 885
Blade Speeds (R.P.M.) 3300
Motor Power (kW/hp) 1.5/2
Voltage (V) 415
Machine Dimension (mm) 700 x 700 x 1400
Nett Weight (kg) 110
1.1 SPECIFICATIONS
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A
B
C
DE
F
G
H
1.2 IDENTIFICATION
I
J
K
L
ABlade Guard HBase
BTrigger Handle IPneumatic Vice Switch
CMist Coolant JTurntable Swivel Locater
DON/OFF Switches KTurntable Swivel Clamp
EControl Box LPneumatic Vices
FMaster Power Switch MFence
GBelt Guard NMovable Blade Guard
M
N
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DO NOT use this machine unless you have read this manual or have been instructed in the use
of this machine in its safe use and operation
This manual provides safety instructions on the proper setup, operation, maintenance, and
service of this machine. Save this manual, refer to it often, and use it to instruct other operators.
Failure to read, understand and follow the instructions in this manual may result in re or
serious personal injury—including amputation, electrocution, or death.
The owner of this machine is solely responsible for its safe use. This responsibility includes, but
is not limited to proper installation in a safe environment, personnel training and authorization
to use, proper inspection and maintenance, manual availability and comprehension, of the
application of the safety devices, integrity, and the use of personal protective equipment.
The manufacturer will not be held liable for injury or property damage from negligence,
improper training, machine modications or misuse.
WARNING
2.1 GENERAL METALWORKING SAFE PRACTICES
Always wear safety glasses or goggles.
Wear appropriate safety footwear.
Wear respiratory protection where required.
Gloves should never be worn while operating the machine, and only worn when
handling the workpiece.
Wear hearing protection in areas > 85 dBA. If you have trouble hearing someone speak
from one metre (three feet) away, the noise level from the machine may be hazardous.
DISCONNECTION THE MACHINE FROM POWER when making adjustments or servicing.
Check and adjust all safety devices before each job.
Ensure that guards are in position and in good working condition before operating.
Ensure that all stationary equipment is anchored securely to the oor.
Ensure all machines have a start/stop button within easy reach of the operator.
Each machine should have only one operator at a time. However, everyone should know
how to stop the machine in an emergency.
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Ensure that keys and adjusting wrenches have been removed from the machine before
turning on the power. Appropriate storage for tooling should be provided.
Ensure that all cutting tools and blades are clean and sharp. They should be able to cut freely
without being forced.
Stop the machine before measuring, cleaning or making any adjustments.
Wait until the machine has stopped running to clear cuttings with a vacuum, brush or rake.
Keep hands away from the cutting head and all moving parts.
Avoid awkward operations and hand positions. A sudden slip could cause the hand to move
into the cutting tool or blade.
Return all portable tooling to their proper storage place after use.
Clean all tools after use.
Keep work area clean. Floors should be level and have a non-slip surface.
Use good lighting so that the work piece, cutting blades, and machine controls can be seen
clearly. Position any shade lighting sources so that they do not cause any glare or reections.
Ensure there is enough room around the machine to do the job safely.
Obtain rst aid immediately for all injuries.
Understand that the health and re hazards can vary from material to material. Make sure all
appropriate precautions are taken.
Clean machines and the surrounding area when the operation is nished.
Use proper lock out procedures when servicing or cleaning the machines or power tools.
DO NOT
×Do not distract an operator. Horseplay can lead to injuries and should be strictly prohibited.
×Do not wear loose clothing, gloves, necktie’s, rings, bracelets or other jewellery that can be
come entangled in moving parts. Conne long hair.
×Do not handle cuttings by hand because they are very sharp. Do not free a stalled cutter
without turning the power o rst. Do not clean hands with cutting uids.
×Do not use rags or wear gloves near moving parts of machines.
×Do not use compressed air to blow debris from machines or to clean dirt from clothes.
×Do not force the machine. It will do the job safer and better at the rate for which it was
designed.
2.1 GENERAL METALWORKING SAFE PRACTICES Cont.
BEFORE OPERATING ANY MACHINE, TAKE TIME TO READ
AND UNDERSTAND ALL SAFETY SIGNS AND SYMBOLS.
IF NOT UNDERSTOOD SEEK EXPLANATION FROM YOUR
SUPERVISOR.
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2.1 GENERAL METALWORKING SAFE PRACTICES Cont.
HAZARDS ASSOCIATED WITH MACHINES include, but are not limited to:
• Being struck by ejected parts of the machinery
• Being struck by material ejected from the machinery
• Contact or entanglement with the machinery
• Contact or entanglement with any material in motion
Health Hazards (other than physical injury caused by moving parts)
• Chemicals hazards that can irritate, burn, or pass through the skin
• Airborne items that can be inhaled, such as oil mist, metal fumes, solvents, and dust
• Heat, noise, and vibration
• Ionizing or non-ionizing radiation (X-ray, lasers, etc.)
• Biological contamination and waste
• Soft tissue injuries (for example, to the hands, arms, shoulders, back, or neck) resulting
from repetitive motion, awkward posture, extended lifting, and pressure grip)
Other Hazards
• Slips and falls from and around machinery during maintenance
• Unstable equipment that is not secured against falling over
• Safe access to/from machines (access, egress)
• Fire or explosion
• Pressure injection injuries from the release of uids and gases under high pressure
• Electrical Hazards, such as electrocution from faulty or ungrounded electrical
components
• Environment in which the machine is used (in a machine shop, or in a work site)
Machines are safeguarded to protect the operator from injury or death with the placement of
guards. Machines must not be operated with the guards removed or damaged.
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2.2 MITRE SAW SAFETY
DO NOT use this machine unless you have been instructed in its safe use and
operation and have read and understood this manual
Safety glasses must be
worn at all times in work
areas
Long and loose hair must
be contained.
Long and loose hair must
be contained.
Sturdy footwear must be
worn at all times in work
areas
Close tting/protective
clothing must be worn
Rings and jewelery must
not be worn.
PRE-OPERATIONAL SAFETY CHECKS
Locate and ensure you are familiar with all machine operations and controls.
Ensure all guards are tted, secure and functional. Do not operate if guards are missing or faulty.
Ensure the saw base is properly secured to the oor by bolts
Ensure the saw is operated on an RCD protected circuit.
Check workspaces and walkways to ensure no slip/trip hazards are present.
Keep table and work area clear of all tools, and aluminium o-cuts.
Start the mist coolant before using the machine.
OPERATIONAL SAFETY CHECKS
Ensure all adjustments are secure before making a cut.
Use clamps to secure and support the workpiece to a stable platform. Make sure that the workpiece
is clamped hard up against the fence.
Before turning on the saw, perform a dry run of the cutting operation to ensure no problems will
occur when the cut is made.
Avoid reaching over the saw line. Do not cross arms when cutting.
When pulling the saw down with your right hand, keep the left hand, especially the thumb, well
clear of the line of cut.
After nishing the cut, release the switch, hold the saw arm down and wait for blade to stop before
removing work or o-cut piece.
Before making any adjustments, disconnect the machine from the power source and bring the
machine to a complete standstill.
DON’T
Do not use faulty equipment. Immediately report suspect equipment.
Do not exceed the maximum cut for the machine.
Do not cut more than one workpiece at a time.
Do not start the saw with the blade touching the workpiece. Allow the blade to reach full speed
rst.
POTENTIAL HAZARDS AND INJURIES
rSaw may grab and ‘kick-back’ toward operator.
rFlying metal chips and airborne coolant.
rContact with rotating blade.
rEye injuries.
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Fig.2
2.3 SITE PREPARATION
On the day that the machine arrives, make sure that a crane or forklift with sucient capacity is
available to unload the machine from the vehicle. Ensure access to the chosen site is clear and
that doors and ceilings are suciently high and wide enough to receive the machine.
To handle the machine, the slings should be positioned so the machine is level when lifted.
When lifting the machine only certied lifting slings should be used. Ensure that when lifting,
the machine does not tip over. Check that the lifting slings do not interfere with the hydraulic
pipes or electrical conduits.
Failure to follow these instructions could cause damage to the machine.
When selecting the site for the machine, consider the largest size of workpiece that will be
processed through the machine and provide enough space around the machine for operating
the machine safely. Consideration should be given to the installation of auxiliary equipment.
Leave enough space around the machine to open or remove doors/covers as required for the
maintenance and service as described in this manual.
It is recommended that the machine is anchored to the oor to prevent tipping or shifting. It
also reduces vibration that may occur during operation.
2.4 SHIPPING CONTENTS
Contents of the Carton
1 Machine body (A) FIG 2
1 Backgauge Seat Right Plate (B FIG 3
1 Operating Instructions/Parts List (Not shown)
A
Fig.3
B
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3.1 ASSEMBLY
You will nd the replacement vise plates in side
of the machine stand.
Attention:
The vise plate is only used for 90 degree cutting
(saw arm angle)
Fig. 4
3.2 BASIC CONTROLS
Main Isolating Switch: This switch isolates all
the power foam the machine. (A in Fig.5)
Motor ON/OFF Switch: This switch energies the
power to the controls (B in Fig.5)
Trigger Switch: This switch starts and stops the
rotation of the blade (C in Fig. 5)
Pneumatic Vise Control: This toggle switch
controls the ON/OFF feature of the pneumatic
vises. The control has three functions. (Fig. 6)
1. On: Closes the Pneumatic vices
2. OFF: Opens the Pneumatic vices
3. Auto:. Automatically closes the vises
when the arm of the saw is pulled down to
start the cut and after the cut its nished
and the saw is returned to its up right
position then releases the vises, ready for
the material to move to the stop.
Fig. 5
CA
Fig. 6
B
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Place the machine near an existing power source. Make sure all power cords are protected from
trac, material handling, moisture, chemicals, or other hazards. Make sure there is access to a
means of disconnecting the power source. The electrical circuit must meet the requirements for
415V. To minimize the risk of electrocution, re, or equipment damage, these machines should
be hard wired with installation work and electrical wiring done by a qualied electrician.
NOTE : The use of an extension cord is not recommended as it may decrease the life of electrical
components on your machine.
3.3 ELECTRICAL INSTALLATION
ELECTRICAL REQUIREMENTS
Nominal Voltage..........................................415V
Cycle.............................................................50 Hz
Phase................................................Three Phase
Power Supply Circuit.............................15 Amps
Full Load Current..................................3.2 Amps
(Full load current rating is also on the specication plate on the motor.)
The full-load current rating is the amperage a machine draws when running at 100% of the out-
put power. Where machines have more than one motor, the full load current is the
amperage drawn by the largest motor or a total of all the motors and electrical devices that
might operate at one time during normal operations.
Full-Load Current Rating for these machine at 415V is 3.2 Amps
It should be noted that the full-load current is not the maximum amount of amps that the
machine will draw. If the machine is overloaded, it will draw additional amps beyond the
full-load rating and if the machine is overloaded for a long period of time, damage, overheating,
or re may be caused to the motor and circuitry.
This is especially true if connected to an undersized circuit or a long extension lead. To reduce
the risk of these hazards, avoid overloading the machine during operation and make
sure it is connected to a power supply circuit that meets the requirements.
3.4 FULLLOAD CURRENT RATING
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3.7 OIL MIST COOLANT
The saw needs to be connected to the air supply,
(Fig.7) that is regulated at 6 - 8 bar. If the machine is
installed on a multi use air line then an additional reg-
ulator may need to be installed. Various functions of
the saw are carried out by the use of the compressed
air.
When using this saw situations may arise where
machine parts & materials are clamped together and
could potentially pose a serious safety issue to an
inexperienced operator. Operators should be
thoroughly instructed about these hazards.
3.5 COMPRESSED AIR SUPPLY
Fig. 7
It is important that the blade is kept cool and lubricat-
ed to prevent jamming.
For this reason a mist coolant system has been installed
on the machine. The coolant mist is adjusted similar to
a spray gun with two controls. One for the coolant and
one for the air supply. The correct quantity is trial and
error and should be set before cutting.
Hafco Metalmaster recommend the use of
Aluminium Spray mist oil, (Hafco Code is S070)
Air-actuated cylinders are used to operate the
Pneumatic Vice Clamps. The clamping action is ideal
for quick clamping in production operations, and yet
is also suitable to use on short run jobs.
Clamp Adjustment:
Adjustment is done by rst releasing the levers &
then moving the cylinder holders to the left or right,
up or down or moving the cylinders in or out.
3.6 PNEUMATIC VICE CLAMPS
Hafco recommend that footwear with anti-slip soles be worn at all times.
Any spills will result in potentially hazardous slippery surfaces & should be dealt with promptly
to prevent physical injury resulting from falls. Some coolants mixed with sawdust or old rags
could become a re hazard
Fig.8
Fig.9
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4.1 SETTING AND ADJUSTMENT
Adjustment of the table angle.
The turntable can be turned right or left.
Preset points at 15°, 22 1/2°, 30°, 45° and in center
position at 90° are set into the table.
To turn the table to these positions,
1. Release the lock lever (C in Fig 10).
2. Pull out the locating pin (D in Fig 10) and move
the saw motor arm by rotating the turntable.
3. When the xed pointer, located on the base is
indicating the required setting on the scale
(Fig.11) (marked on the turntable), release the
locating pin. (D in Fig.10) If the desired angle is
one of the following angles, 15°, 22 1/2°, 30°,
45° or 90°, then the pin will locate in the preset
position for that angle.
4. Once the angle has been set then tighten the
lever lock (C in Fig.10) to prevent the turntable
moving during the operation.
C
D
Fig.10
4 OPERATION
Fig.11
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Adjusting the arm angle
The saw motor arm can only be tilted to the left and
to a maximum angle of 45°. (Fig.12)
The arm is tilted as follows:
1. Undo the lock screw, (L in Fig.13), at the back of
the machine.
2. Using the hand-grip, tilt the saw motor arm to the
required angle on the scale next to the hinge.
(Fig.13)
3. Once you have tilted the motor arm to the angle,
lock the screw again (L in Fig.14)
Fig.12
Fig.13
NOTE: During the adjustment operations, keep a rm hold on the handle and make sure to
avoid pinch and crush points.
4.2 SETTING AND ADJUSTMENT Cont.
Fig.14
L
Setting Pnuematic Vise Clamps
Adjustment is done by rst releasing the levers &
then moving the cylinder holders to the left or right,
up or down or moving the cylinders in or out. For
your safety and for eective clamping it is important
the pneumatic clamps are set within 4mm of the
workpiece. (Fig.15)
Fig.15
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4.3 CUTTING OPERATION
MANUAL MODE
1. Connect the pressure air supply to the male socket
(Fig 16).
2. Push green button of the main switch (B in Fig 17) to
power the machine.
3. Position the material to be cut on the working base
pushed against the fence.
4. Clamp workpiece by turning the toggle switch to ON
(Fig 18).
NOTE: For your safety and for eective clamping it is im-
portant the pneumatic clamps are set within 4mm of the
workpiece.
5. Use the handle (A in Fig.17) to lower the blade close
to the material to be cut, then press the trigger (C In
Fig.17) to start the blade and pull down gradually until
you have completed the cut.
6. When you have completed the cut, release the trigger
(C In Fig.17) and return the saw/motor arm back to its
upright position.
7. Release the material by turning the toggle switch to OFF
(Fig 18).
NOTE: Pushing down harder on the handle does not neces-
sarily mean that the cut will be faster, in fact this can lead to
the motor overloading, and result in a less ecient
operation.
AUTOMATICE MODE
1. Connect the pressure air supply to the male socket (Fig 16).
2. Push green button of the main switch (B in Fig 17) to Power the machine.
3. Position the material to be cut on the working base pushed against the fence.
4. Select toggle switch to AUTO (Fig 18).
NOTE: For your safety and for eective clamping it is important the pneumatic clamps are set
within 4mm of the workpiece.
5. Use the handle (A in Fig.17) to lower the blade, this will active the pneumatic clamps, when
close to the material then press the trigger (C In Fig.17) to start the blade and pull down
gradually until you have completed the cut.
6. When you have completed the cut, release the trigger (C In Fig.17) and return the saw
motor arm back to its upright position which will automatically release the material.
Fig.17
B
C
A
Fig.18
Fig.16
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MAINTENANCE
Maintenance must be carried out by qualied sta. It is compulsory to disconnect the machine
from both the power and the air supply when adjusting or repairing the machine.
5.1 LUBRICATION SCHEDULE.
1. Lubricate the saw head pivot shaft & rotary table, after every 40 hours of operation with,
Shell Alvania No.1 grease or equivalent.
2. Clean the vice & lubricate any moving joints or sliding surfaces with good quality oil.
3. Clean the machine regularly & keep the machined surfaces lightly oiled to protect from
rust & corrosion.
4. Disconnect the air line and place some drops of air tool oil in the connector on the machine
to prevent corrosion of the pneumatic system.
5.2 TROUBLESHOOTING.
Review the troubleshooting and procedures in this section if a problem develops with your
machine. If you need replacement parts then follow the procedure in beginning of the spare
parts section or if additional help with a procedure is required, then contact you distributor.
Note: Make sure you have the model of the machine, serial number,and manufacture date
before calling.
Problem Possible Cause Solution
Teeth breaking
Incorrect lubricant/coolant uid. Ensure proper coolant ow.
Material too hard
Check the cutting speed, feed speed
and air pressure parameters and the
type of blade you are using.
Blade not worn--in correctly
With a new blade it is necessary to
start cutting at half feeding speed.
After the wearing--in period (a cutting
surface of about 300 cm2 for hard
materials and about 1000 cm2 for soft
materials) the cutting and feed speeds
can be brought up to normal values
Blade with excessively ne tooth
pitch
Replace the blade with a larger tooth
pitch
New blade inserted in a partially
completed cut
Start a new cut as the material may be
work hardened.
Work piece not clamped rmly
in place
Check the vise, jaws and clamping
pressure.
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Problem Possible Cause Solution
Rapid tooth wear
Feed speed too slow The blade runs over the material without
removing it: increase feed speed
Cutting pressure too high Reduce cutting pressure.
Blade speed too high The teeth slide over the material without
cutting it: reduce the blade speed
Incorrect uid concentration Check and use the correct concentration
Insucient coolant Check the coolant level and clean coolant
lines and nozzles.
Material defective
The materials may have oxides or sand
on the surface, or in section, such as
under-cooled inclusions. These areas, are
much harder than the blade, and cause
the teeth to break. Discard or clean the
materials.
Broken blade
Feed speed too high Reduce blade speed.
Teeth in contact with material
before starting the cut
Always check the position of the blade
before starting a new job.
Insucient coolant Check the coolant level and clean coolant
lines and nozzles
Spindle motor
will not turn
Electrical power supply
Check: the cables, plug and socket. Also
check that the motor connections are in
place.
Transformer
Check that the voltages are present both
on the input and output. Otherwise re-
place
Contactor
Check that the contactor closes when
powered and that it is not causing short
circuits. Change if any of these problems
are found.
Thermal relay
Make sure it is closed. If it has tripped
to protect the motor, check the amper-
age setting, reset, and check the motor.
Change if necessary
Motor
Check that it has not burnt out, that it
turns freely and that there is no moisture
in the connection terminal board box. The
winding can be rewound or replaced.
Troubleshooting Cont.
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5.3 REPLACING THE BLADE
During the life of the saw the blade will need to be
removed to be sharpened or replaced.
The blade teeth are sharp and
can cut very easily. For this operation, wear leather
work gloves for protection.
To Change The Blade.
1. DISCONNECT THE MACHINE FROM THE BOTH
POWER AND THE AIR SUPPLY.
2. Raise the motor arm to its fully up position
3. Release the mechanism of the internal guard by
pushing the point (N in Fig 19), and push up the
guard (O in Fig 19).
4. Place a 6 mm wrench inside the center hole
(Fig.20) of the belt guard to stop the shaft from
moving. At the same time, place an 8mm hex key
in the set screw (S in Fig 21) and loosen the screw
5. Remove screw (S in Fig.21)and remove outer
ange (R in Fig. 21)
6. Mount or remove the blade by taking it out from
the bottom. When retting the blade, make sure
the teeth are facing in the direction shown by the
arrow on the saw arm . To complete the blade
installation, replace the outer ange, R , and
then replace and tighten the screw S.
7. Pull down the internal guard back to its initial
position and reconnect the guard opening
mechanism.
8. Using the handle pull the saw down and ensure
that the inner safety guard is working correctly.
Do not use the saw until the guard is working
correctly.
Fig.19
N
O
Fig. 20
Fig. 22
SR
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SPARE PARTS SECTION
The following section covers the spare parts diagrams and lists that were current
at the time this manual was originally printed. Due to continuous improvements
of the machine, changes may be made at any time without notication.
HOW TO ORDER SPARE PARTS
1. Have your machines model number, serial number & date of manufacture
on hand, these can be found on the specication plate mounted on the
machine
2. A scanned copy of your parts list/diagram with required spare part/s
identied
3. Go to www.machineryhouse.com.au/contactus and ll out the enquiry form
attaching a copy of scanned parts list.
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