Hafco Metalmaster S829 Parts list manual

CS-350V COLD SAW
INSTRUCTION & PARTS MANUAL
13-3-12
S829 S830

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Table of Contents
1 SAFETY REGULATIONS ........................2
1.1 General Safety Advice.......................2
1.2 Blade Guard Safety...........................2
1.3 Emergencies .....................................2
2 MACHINE DIMENSIONS.........................2
3 TECHNICAL CHARACTERISTICS .........3
3.1 General Characteristics.....................3
4 TRANSPORTING THE MACHINE...........3
5 GETTING TO KNOW YOUR MACHINE ..3
5.1 Disk Head Assembly .........................3
5.2 Machine Base ...................................4
5.3 Vice...................................................4
5.4 Support Roller ...................................4
5.5 Stand.................................................4
5.6 Coolant Pump ...................................4
6 GETTING STARTED ...............................5
6.1 Minimum Requirements for Housing
the Machine ............................................5
6.2 Anchoring the Machine......................5
6.3 Assembly and Setup .........................5
6.4 Electrical Connection of the Machine 8
7 RECOMMENDATIONS AND ADVICE.....8
7.1 General Advise Before Using the
Machine ..................................................8
7.2 Operator Position ..............................8
7.3 Deactivating the Machine ..................9
7.4 Dismantling .......................................9
8 ADJUSTING THE MACHINE.................10
8.1 Disk Head....................................... 10
8.2 Adjusting the Mitering Lock Lever... 10
8.3 Changing the Disk .......................... 10
8.4 Cleaning and Accessing the Coolant
System ................................................. 10
8.5 Troubleshooting the inverter ........... 11
8.6 Common Problems and Solutions... 11
9 THE OPERATION CYCLE .................... 14
9.1 Miter Angle ..................................... 14
9.2 Vise Operation................................ 14
9.3 Loading the Work-piece.................. 15
9.4 Setting Cutting Length .................... 15
9.5 Operation Cycle.............................. 15
10 ROUTINE AND SPECIAL
MAINTENANCE....................................... 16
10.1 Daily Maintenance ........................ 16
10.2 Weekly Maintenance .................... 16
10.3 Monthly Maintenance.................... 17
10.4 Six-Monthly Maintenance.............. 17
10.5 Oils for Lubricating Coolant........... 17
10.6 Oil Disposal .................................. 17
10.7 Special Maintenance .................... 17
11 TROUBLESHOOTION ........................ 18
11.1 Blade and cut diagnosis................ 18
12 WIRING DIARAM AND PARTS LIST.. 21
12.1 WIRING DIARAM ......................... 21
12.2 PARTS LIST................................. 22

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1
1S SA AF FE ET TY YR RE EG GU UL LA AT TI IO ON NS S
This machine complies with the national and local accident prevention regulations. Improper
use and/or tampering of the machine will relieve the manufacturer of all responsibility.
1.1 General Safety Advice
Always wear suitable eye protection.
Always disconnect the machine from the power source before changing the saw
blade/cutting disk, or performing any maintenance work.
Never expose your hands or limbs to the cutting area while the machine is operating.
Do not shift the machine while in operation.
Do not wear, gloves, very loose or long clothing, long and loose sleeves, bracelets,
chains, neck ties; or any other object that could get caught in the machine during
operation
Tie back long hair.
Keep the work area free of equipment, tools or any other object.
Focus on one task at a time
Keep your hands free; do not carry too many objects in your hands.
Keep your hands clean.
When the machine is not in use, the saw blade should not be moving.
1.2 Blade Guard Safety
The blade guard is a self –adjusting cover that prevents contact with the blade. Never
use the machine without the blade guard.
Never handle blade guard while the blade is running.
1.3 Emergencies
In the event of incorrect operation or dangerous conditions, the machine may be stopped
immediately by pressing the emergency stop button. This will shut off the machine and will
require resetting of the emergency stop button.
Note: Resetting of machine operation after each emergency stop is achieved by reactivating
the specific restart button.
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2M MA AC CH HI IN NE ED DI IM ME EN NS SI IO ON NS S
990mm
1200mm
1830mm

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3
3T TE EC CH HN NI IC CA AL LC CH HA AR RA AC CT TE ER RI IS ST TI IC CS S
3.1 General Characteristics
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4T TR RA AN NS SP PO OR RT TI IN NG GT TH HE EM MA AC CH HI IN NE E
When transporting in its own packaging, use a forklift truck or
hand trolley.
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5G GE ET TT TI IN NG GT TO OK KN NO OW WY YO OU UR RM MA AC CH HI IN NE E
5.1 Disk Head Assembly
The section of the machine composed motor, gear transfer
system, disc or blade, and control handle.
A. Control Lever
A long angled lever with a handle grip and trigger switch for
starting, raising, and lowering the disk head
B. Transfer Case
The central part of the assembly, housing the gear system
and oil tank.
Cutting
Capacity
0 ْ ◌
85mm 3.5”
120mm 4.7”
105 x 105mm
4” x 4”
160 x 90mm
6.3” x 3.5”
45 ْ ◌
75mm 3”
100mm 4”
85x 85mm
3.5“ x 3.5”
85 x 70mm
3.5” x 2.8”
Main Motor
3 HP / 4pole
Spindle Speed
24~120RPM
Saw Blade
HSS 2.5mm x 32 x Ф 350 mm
Maximum Vise Opening
170 mm 4.7”
Cooling Pump
1/8 HP
Coolant tank
5 L
Machine Weight (KGS)
250 kgs (with stand)
Machine Dimensions
(with stand) L x W x H
1200 x 990 x 1720mm
47” x 39” x 67.7”
Stand Dimensions
600 x 580 x 720 mm
23.6” x 22.8” x 28.3”
B
A

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5.2 Machine Base
A heavy cast iron structure that supports the miter system,
vise system, and head assembly.
5.3 Vice
Aclamping system that provides the basic support and
security for the work material. Operations are conducted by
hand-wheel, which opens and closes the vise jaws.
The clamping vise can be adjusted forward and backward to
clamp workpiece of various sizes.
5.4 Support Roller
A Device that support longer sized material. The roller
assists stock moving through the vise.
5.5 Stand
Support structure for the Machine Head Assembly, Machine
Base, and Vise system. The stand also stores electrical
control box at the front and coolant pump at rear.
5.6 Coolant Pump
Found within the machine stand, the coolant pump is a self
contained system that includes a tank, pump motor, filters
and hoses.

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6
6G GE ET TT TI IN NG GS ST TA AR RT TE ED D
Make sure that the electrical supply and the machine’s voltage are the same. Refer to
the identification plate on the motor for the correct voltage.
Use a good quality grounded electrical system.
All internal and/or internal operations, maintenance or repairs, must be performed in a
well-lit area or where there is sufficient light from extra sources so as to avoid the risk of
even slight accidents.
6.1 Minimum Requirements for Housing the Machine
The Main voltage and frequency complying with the requirements for the machine’s motor.
Environment temperature from –10°C to +50°C.
Relative humidity not over 90%.
6.2 Anchoring the Machine
Position the machine on a firm and level concrete floor.
Maintain a minimum distance of 800mm from the wall to
rear of the machine.
Anchor the machine to the ground, as shown in the
diagram, using screws and expansion plugs or sunken
tie rods that connect through holes in the base of the
stand.
Ensuring that it is sitting level.
6.3 Assembly and Setup
Positioning the machine
Please follow the instruction bellow when unpacking the machine
from the package.
Take out the accessory box from the rear for assembling
some parts later.
Take out the machine from the package to the intended
working location by hoisting with the belts. The load capacity
is about 300kgs at point E.
Method one: Use a sling. Carefully wrap the sling (E) around
the collar of the moveable jaw and motor mount.
Method two: Using lift rings. Attach lifting rings to three points
on the base of the machine. Attach a three-point sling with
grab or sling hooks to the lift rings.
Initial Cleaning
Machine is shipped with rustproof oil coating. Clean the rust
proof oil coating from all exposed metal surface. Then apply
oil / grease.
The stand of the cold saw has four mounting holes, two holes
on each side of the stand( ). The cold saw should be kept
level and rest solidly on the floor.
Please refer to the anchoring section above. When securing
the stand to the floor, apply even torque to the fasteners to
prevent distortion of the stand.
E
E
1
2

6
The machine has been fixed on the stand already to use.
Giving the picture by appearing the foxing points for reference.
Align the four setscrews (G) on the underside of the machine
base to their corresponding holes in the stand.
Direct the setscrews (G) into their matching holes while
lowering the machine onto the stand.
Secure the machine onto the stand using three nuts to the
exposed setscrews.
The coolant tank platform has been fixed on already. The
following is for your reference.
Insert platform (H) to the interior of the machine stand.
Align the platform holes (i) to the screw holes (i) on the
interior of the machine stand.
Apply an M8x18x2, washer to each of the 2 M8x12 screws.
Secure the platform (H) to the stand.
Use a wrench to unscrew a M20 X 40 hex head screw (J)
from the oil fill hole (J).
Attach the control handle to the head assembly.
Insert the threaded end of the control handle into the gear oil
fill hole (J).
Turn the control handle (L) along the shaft to screw in the
control handle (L) until a tight fit.
Align the handle (L) so that the trigger switch (K) point up.
(Refer to image)
Connect the electric wire with the motor.
Locate the open socket (M) at the side of the electrical box on
the top of the motor.
Plug in the control handle cable into the open socket (M).
Use a wrench to screw in the cable connecter nut (N).
Attach the support roller to the left side of the base.
Place the support roller (P) up next to the machine base.
Align the 2 slots (O) in the base of the support roller with the
matching screw holes on the base of the machine.
Apply an M10 washer for each of 2 M10x25 hex head bolts.
Loosely screw the hex head bolts into the aligned slot (O) and
holes.
Adjust the height of the support roller (P). Place a level
across the mouth of the vise and support roller. If a long level
in not available, use a straight bar or piece of material then
place a small level on top. Raise or lower the support roller
until level.
Secure the support roller (P) into place. Use a wrench to
tighten down the 2 hex head bolts.
5
J
7
N
M
6
K
L
J
8
O
P
G
G
G
G
4
H
i
3

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Attach the bar stop to the vise.
Insert the thread end of the long rod (R) into the side of the
vise.
Turn the long rod clockwise until snug.
Use a hex wrench 5mm to lock the screw M12x10 (Q) on the
sleeve counter-clockwise, so that bar stop unit is secure.
Assemble the coolant tank
Insert the coolant pump (X) into the coolant tank (T).
Apply an M6 washer to each of 2 M6x20 screws (U).
Secure pump (X) to tank (T) with prepared screws (U).
Place the hose clamp (V) onto the 0.375” flow tube (W).
Connect the flow tube (W) to the hose connector (V).
Use a flat head screwdriver to tighten the hose clamp (V).
Install the coolant tank
Orient the coolant pump (X) towards the rear opening of
machine stand.
Place the coolant tank (1A) onto the coolant platform (H).
The coolant tank (1A) contains a divider that forms a trough in
the bottom of the tank. This trough fit over the vertical lip of
the coolant platform (H).
Insert one end of the 0.5” drain hose (Y) onto the hose
connector (1B) on the underside of the machine base.
Place the other end into the insert (Z) of the coolant tank (1A).
Attach the rear plate to the back of the stand.
Place rear plate (1C) across the back of the machine stand.
Align the plate holes (1D) with the set of 4 holes towards the
top of the machine stand.
Apply an M8 washer to each of 4 M8x25 screws.
Secure with 4 screws and washers.
Install the splash plates
Insert a splash plate (1E) onto the front sidewall of machine
base.
Align the 2 slots (1F) in the base of the splash plate with the
matching screw holes on the machine base.
Apply a washer for each of 2 hex socket head screws M8x20.
Loosely screw the socket hex head screws into the aligned
slot (1F) and holes.
Adjust the splash plate (1E) to the proper position and tighten
down the screws to secure.
Insert a longer one of splash plate (1G) onto the rear sidewall
of the machine base. This plate need not be secured with
screws to allow free movement or convenient removal.
11
12
9
Q
R
10
X
U
V
W
T
1A
X
Z
Y
13
H
1B
1C
Y
1D
1D
1E
1F
1G

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6.4 Electrical Connection of the Machine
Make sure whether the voltage of the acquired machine is
220V/ 1 phase or (220V,380V,400,440V)/ 3 phase prior to
connection.
The control electrical box is located at the front of the stand
with a latching door.
The power connection cable is at the rear of the electrical box
as shown in the picture (6.4 -1).
This machine uses an inverter to change the speed rate from
24~120rpm. Please refer to the information in front of the
window on the control panel.
If the machine cannot be operated after wires have been
connected, please check the following items:
1. The Emergency switch is released.
2. The door of the electrical cabinet is properly closed and
switched ON (locked).
3. Refer to the Table of Error Codes for the inverter ( 8.6).
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7R RE EC CO OM MM ME EN ND DA AT TI IO ON NS SA AN ND DA AD DV VI IC CE E
7.1 General Advise Before Using the Machine
This machine is designed to cut metal construction materials of different shapes and profiles. The
materials may be required for fabrication workshops, machinist shops, and general construction
work.
Limit the machines use to a single operator.
To obtain good running-in of the machine it is advisable to start using it at intervals of about half
an hour. This operation should be repeated two or three times, after which the machine may be
used continuously.
Always check that the workpiece is securely clamped and that long pieces are suitably supported.
Do not use a disk size that is outside the limits of the machine specifications.
Immediately release the start/run/trigger button if the disk should get stuck in a cut. Switch off the
machine before raising the machine head. Then open the vise and remove the workpiece.
Lastly, check the disk teeth for any damage. If any of the teeth are broken, replace the saw
blade.
Before carrying out any repairs of the machine, consult a technician.
7.2 Operator Position
The operator should stand in front of the machine using a single
hand to grip the control handle.
6.4-1

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7.3 Deactivating the Machine
If the machine is to be inactive for a long period, prepare the machine as follows:
Detach the plug from the electric supply panel
Release the head return spring
Empty the coolant tank
Carefully clean and grease the machine
If necessary, cover the machine.
7.4 Dismantling
General rules
Before disposing of the machine, the machine should be broken down and separated into the 3
categories as follows:
Cast iron or ferrous materials: These materials should be of single composition, without
combination or attachment to other types of materials. This is a recyclable material. The
materials may be sent to metal scrap and recycling centers.
Electrical components: This includes cables and electronic parts (magnetic cards, etc.). These
materials may be considered as urban waste. Give the materials to your local public waste
disposal service.
Old mineral, synthetic and/or mixed oils: Blend oils and greases are special refuse. Have these
collected by a service specializing in oil disposal.
Note: Standards and legislation for waste disposal is in a state continuous change and evolution.
The user must be informed of current regulation for waste disposal of machine tools, as they may
differ from those described above. They are to be considered as general guideline.

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8
8A AD DJ JU US ST TI IN NG GT TH HE EM MA AC CH HI IN NE E
BEFORE PERFORMING THE FOLLOWING OPERATIONS, THE ELECTRIC POWER SUPPLY AND
THE POWER CABLE MUST BE COMPLETELY DISCONNECTED.
8.1 Disk Head
If excessive axial play is found on the hinge, it will be sufficient to tighten the screws.
Pay attention and avoid making the joint too tight.
8.2 Adjusting the Mitering Lock Lever
The lock lever may require adjustment when the lever is limited by
the machine base and it fail to adequately secure the miter angle
for machine head. If there is insufficient brakeage of the lock
lever:
Loosen screw (A)
Support the bushing (B) so that it does not drop in position.
Pivot the lever (C) to unlock side to allow more range of
motion.
Then tighten the screw (A).
8.3 Changing the Disk
To changed the disk:
Release the mobile guard (A) by removing the hex socket
screw (B).
Rotate the mobile guard (A) back.
Place a block of wood into the vise.
Lower the machine head to rest the cutting disk or saw blade
on the block of wood.
Use a hex wrench to remove the hex socket screw (C),
Rotate the disk in the clockwise direction to loosen it
(because it has a left-handed thread).
Remove the disk or blade (D) and flange (E) from the head
assembly.
Slip off the flange (E) from the disk (D).
Place the flange onto the replacement disk or blade (D).
Continue the replacement of the disk in reverse order of
removal of the disk.

8.4 Cleaning and Accessing the Coolant System
Pull out the drain hose from the filter (A).
Pull out the coolant tank from the coolant platform in the
stand.
Remove the filter (A) from the tank
Pour out the coolant
Wash out the dirt and debris.
Replace the filter (A).
Fill with coolant solution of 1:10 ratio of coolant to water
Replace the coolant tank in reverse order of removal.
C
A
B
A
C
B
D
E
A

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8.5 Troubleshooting the inverter
Troubleshooting the inverter
Prior to operating all electronic parts, the following aspects should be taken into consideration first
Note: Only eligible and qualified personnel can make electronic adjustments.
1. Disconnect machine from power supply.
2. Electronic parts are extremely sensitive, do not use hands or metal tools to remove or install such
parts.
3. As remaining voltage still exists in the capacitor even after the electric current has been cut off,
wait until the light disappears from the lighted display completely before proceeding with any work
to prevent any accidents or hazards from occurring.
4. Pay close attention to the electronic circuit board so that they are free from any defects.
5. Never connect the alternating current directly to the output connector (U/V/W) of the speed
adjuster. The electronic self-diagnosis program can notify you of situations like motor overloading
and too low or too high voltage, etc. When the program detects an error, the machine will stop
immediately and such error will be displayed on the inverter’s digital display. Follow the solutions
to correct any errors. Close the electrical cabinet and connect machine to power supply.
6. Wait 5 seconds after a fault has been cleared before performing reset via keypad of input
terminal.
8.6 Common Problems and Solutions

12

13

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9
9T TH HE EO OP PE ER RA AT TI IO ON NC CY YC CL LE E
Before operating all the main parts of the machine must be set to optimum conditions (see the chapter
on “regulating the machine”)
9.1 Miter Angle
Use the miter lock lever (A) to release the disk head
assembly.
Rotate the disk head assembly to the correct miter angle.
Check the miter angle on the angle indicator (B) below the
vise
Use the miter lock lever (A) to lock in the miter angle.
9.2 Vise Operation
The quick clamp vise lever allows the operator to quickly clamp and unclamp work-pieces of same
width. This allows for efficient use of machine for loading and feeding forward work-pieces.
Use the hand wheel to open and close the vise jaw for work
pieces that vary in width.
Rotate the hand-wheel (A) counter-clockwise to open the
vise.
Rotate the hand-wheel (A) clockwise to close and approach
the vise jaw (C) to the work pieces.
Use the vise lever to quickly clamp and unclamp work pieces of
the same width.
Rotate the vise lever (B) clockwise to clamp the work-piece.
Rotate the vise lever (B) counter-clockwise to unclamp the
work-piece.
The clamping vise set equips with the function to adjust forward
and backward for extending the clamp capacity.
There is a sliding devise between the swing base and the bottom
of the vise. Please refer to the indicator on picture (9.1 D).
Pull out the vise set that the entire vise ti come out and vice
versa.
The clamping vise equips with another function for making the slot
cutting in the head was set in 90 degree.
Take off the set of bar stop of setting cutting measurement.
Use a hex wrench 5mm to loss the M6x10 screw on the long
rod (Q-6.3 pic.-9 ).
Loosen the miter lock lever (9.1 A).
Rotate the entire dick head unit to the right, checking the
angle on the indicator (9.1, B) at the 90 degree of vise.
Upload the material and clamp it securely before cutting.
A
B
C
A
B
D

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9.3 Loading the Work-piece
Use the vise hand-wheel to open the vise wider than the width of the work-piece.
Measure and mark off the length of material desired to be cut-off.
Place the work-piece on the flat surface in between the vise jaws.
Slide the work-piece across the vise so that the length mark lines up with the blade or disk.
Press the work-piece up against the back vise jaw.
Use the vise hand-wheel to clamp the work-piece.
If repetitive cuts are required for material of the same width:
Use the vise hand-wheel to approach the work-piece, but leave an approximate 5mm gap
between the mobile vise jaw and the work-piece.
Then use the vise lock lever to clamp and unclamp the work-piece.
Decrease vibration (workpiece position setting)
The clamping vise can be adjusted forward and backward to clamp work-piece for various
size.
Please be followed the trick as below when loading (setting) the work-piece position for
decreasing the vibration.
1. check the workpiece’s center not over the center of blade. Please see drew A
2.
9.4 Setting Cutting Length
Setting the cutting length removes the need to repeatedly measure work-pieces for repetitive cuts of a
single length.
Measure and mark off the length of material desired to be cut-
off.
Load the work-piece.
Line up the cut
Clamp the work-piece.
Loosen the hex nut at the base of the bar riser (A).
Slide the bar riser (A) along the long rod (C) so that the tip of
stop bar (B) touches the end of the work-piece.
Tighten the hex nut at the base of the bar riser (A).
The stop bar in use
Cut off the first length of work-piece.
Unclamp the work-piece
Slide the work-piece forward until it reaches tip of the stop bar (A).
Clamp the work-piece.
Then proceed with the operation cycle
9.5 Operation Cycle
Set the miter cut angle, if necessary
Open the vise, if necessary
Load the work-piece
Clamp the work-piece
Adjust the bar stop for cutting length, if necessary
Check that the main power light is ON (A).
A
B
C
H
E
C
D
A
B

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Set the speed (C), read the speed displayed on the window
(H).
Set the coolant switch (B).
Grasp the control handle (G).
Press the trigger switch (F) to start.
Pull down the control handle (G). Apply a steady and
constant pressure.
After cut off
Raise control handle slowly
Press the stop button (D)
Use vise lever to open the vise
Remove or feed the work-piece forward
Repeat operation cycle, if necessary
The chopper is now ready to start work, bearing in mind that the CUTTING SPEED and the TYPE of
DISC – combined with a suitable descent of the head – are of decisive importance for cutting quality
and for machine performance.
When starting to cut with a new disk, in order to safeguard its life and efficiency, the first two or three
cuts must be made while exerting a slight pressure on the part, so that the time taken to cut is about
double the normal time.
Press the red emergency button (E) when there are conditions of danger of malfunctions in general,
so as to stop machine operation immediately.
1
10 0R RO OU UT TI IN NE EA AN ND DS SP PE EC CI IA AL LM MA AI IN NT TE EN NA AN NC CE E
THE MAINTENANCE SCHEDULE AS BEEN DIVIDED INTO DAILY, WEEKLY, MONTHLY,
AND SIX-MONTHLY INTERVALS. NEGLECTING THE MACHINE MAINTENANCE WILL
RESULT IN PREMATURE WEAR AND POOR PERFORMANCE.
10.1 Daily Maintenance
Make a general cleaning by removing dust and shavings from the machine.
Top off the coolant.
Inspect the disk/saw blade for wear.
Raise the head into a high position to reduce stress on the return spring.
Check that the shields and emergency stops are in good working order.
10.2 Weekly Maintenance
Thoroughly clean the machine including the coolant tank.
Clean and grease the vice screw and sliding surfaces.
Clean the housing for disk/saw blade.
Sharpen the saw teeth.
F
G

17
10.3 Monthly Maintenance
Check that all screws on the motor, the pump, the vise jaws, and the guard are tight and secure.
Check that the guard is free from defect.
Grease the hinge pin for the head assembly.
10.4 Six-Monthly Maintenance
Change the oil in the reduction unit using oil type DN SUPER GEAR 460 by IDEMITSU or DAPHON
or equivalent oil, proceeding as follows:
Remove the connecting plug from the electric box and unscrew
the control handle.
Drain off the old oil from the drain hole (B )
Pour in new oil of to the mark (A), through the hole for the control
handle, keeping head in a horizontal position.
Full the oil up at least 1.5 liters.
Reassemble all the parts.
Check continuity of the equipotential protection circuit.
10.5 Oils for Lubricating Coolant
Considering the vast range of products on the market, the user can choose the one most suited to his
own requirements, using as reference the type SHELL LUTEM OIL ECO.
THE MINIMUM PERCENTAGE OF OIL DILUTED IN WATER IS 8~10%.
10.6 Oil Disposal
Oil products must be disposed in a proper manner following local regulations. Please refer to
“Machine disposal.”
10.7 Special Maintenance
Special maintenance operations must be carried out by skilled personnel. However, we advise
contacting dealer and/or importer the term special maintenance also covers the resetting of protection
and safety equipment and devices.
B
A

18
1
11 1T TR RO OU UB BL LE ES SH HO OO OT TI IO ON N
This chapter lists the probable faults and malfunctions that could occur while the machine is
being used and suggests possible remedies for solving them.
The first paragraph provides diagnosis for TOOLS and CUTS, the second for ELECTRICAL
COMPONENTS.
11.1 Blade and cut diagnosis
FAULT
PROBABLE CAUSE
REMEDY
TOOTH BREAKAGE
Too fast advance
Wrong cutting speed
Wrong tooth pitch
Low quality disk
Ineffective gripping of the part in the vise.
Previously broken tooth left in the cut.
Cutting resumed on a groove made
previously.
Insufficient lubricating refrigerant or
wrong emulsion.
Sticky accumulation of material on the
disk.
Decrease advance, exerting less cutting
pressure.
Change disk speed and/or diameter.
See chapter “ Material classification and
choice of disks” and the Table of cutting
speed s according to disk diameter.
Choose a suitable disk.
See chapter “ Material classification and
choice of disks”.
Use a better quality disk.
Check the gripping of the part.
Accurately remove all the parts left in.
Make the cut elsewhere, turning the part.
Check the level of the liquid in the tank.
Increase the flew of lubricating
refrigerant, checking that the hole and
the liguid outlet pipe are not blocked.
Check the blend of lubricating coolant
and choose a better quality disk.
PREMATURE DISK
WEAR
Wrong running in of the disk .
Wrong cutting speed.
Unsuitable tooth profile.
Wrong tooth pitch.
Low quality disk.
Insufficient lubricating refrigerant.
See chapter “ Material classification and
choice of disks” in the paragraph on
Running in the disk.
Change disk speed and / or diameter.
See Chapter “ Material classification and
choice of disks” and the Table of cutting
speeds according to disk diameter.
Choose a suitable disk. See Chapter
“ Material classification and choice of
disks” in the paragraph on Type of disks.
Choose a suitable disk.
See Chapter “ Material classification and
choice of disks”.
Use a better quality disk.
Check the level of the liquid in the tank.
Increase the flow of lubricating
refrigerant, checking that the hole and
the liquid outlet pipe are not blocked.

19
FAULT
PROBABLE CAUSE
REMEDY
CHIPPED DISK
Hardness, shape or flaws in the material
(oxides, inclusions, lack of homogeneity,
etc…)
Wrong cutting speed.
Wrong tooth pitch.
Vibrations
Disk incorrectly sharpened.
Low quality disk.
Incorrect emulsion of the lubricating
Refrigerant.
Reduce the cutting pressure and/or the
advance.
Change disk speed and/or diameter. See
Chapter ”Material classification and
choice of disks” and the Table of cutting
speeds according to disk diameter.
Choose a suitable disk.
See Chapter “Material classification and
choice of disks”.
Check gripping of the part.
Replace the disk with one that is more
suitable and correctly sharpened.
Use a better quality disk.
Check the percentage of water and oil in
the emulsion.
DISK VIBRATION
Wrong tooth pitch.
Unsuitable tooth profile.
Ineffective gripping of the part in the vise.
Dimensions of the solid section too large
with respect to the maximum admissible
cutting dimensions.
Disk diameter incorrect and/or too large.
Choose a suitable disk.
See Chapter “Material classification and
choice of disks”.
Choose a suitable disk.
See Chapter “Material classification and
choice of disks” in the paragraph on Type
of disks.
Check the gripping of the part.
Abide by the instructions.
Decrease the disk diameter, adapting it
to the dimensions of the part to be cut,
the cutting part of the disk must not be
too large for the shape of the part to be
cut.
RIDGES ON THE
CUTTING SURFACE
Disk diameter incorrect and/ or too large.
Ineffective gripping of the part in the vise.
Too fast advance.
Disk teeth are worn.
Insufficient lubricating refrigerant.
Toothing does not unload shavings well.
Decrease the disk diameter, adapting it
to the dimensions of the part to be cut,
the cutting part of the disk must not be
too large for the shape of the part to be
cut. Check the gripping of the part.
Decrease advance, exerting less cutting
pressure.
Sharpen the tool.
Check the level of the liquid in the tank.
Increase the flow of lubricating
refrigerant, checking that the hole and
the liquid outlet pipe are not blocked.
Choose a blade with a larger tooth pitch
that allows better unloading of shavings
and that holds more lubricating
refrigerant.