KARMETAL KMT 280 WOS User manual

KK47(24.01.2017/00)
KMT
280 WOS
OPERATION MANUAL

2
MACHINE CERTIFICATION AND IDENTIFICATION
MARKING
NOTE : This manual is a part of the machine and must accompany it if
moved within the company or sold.
ATTENTION!!!
BEFORE USING THE MACHINE, PLEASE READ THIS
MANUAL CAREFULLY. ALL EXPLANATIONS,
INSTRUCTIONS AND WARNINGS ARE INTENDED TO
PROTECT YOU!

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EC DECLARATION OF CONFORMITY
The manufacturer declares that the machinery described herein conforms to
the following EC directives and harmonised standards and relevant essential
health and safety requirements.
Manufacturer: KARMETAL SAN. & TIC. LTD. STI
Address: Hanlı Merkez Mah. Hatip Sok. No: 32 Arifiye/Sakarya/ TURKEY
Phone: [phone] (3 lines)
Fax: [phone]
Web: www.karmetal.com.tr
e-mail: [email protected]
Machine type/model: KMT 280 WOS Automatic PLC Controlled Band Saw Machine
Applicable EC Directives:
Machinery Directive 2006/42/EC,
Low Voltage Directive (LVD) 2006/95/EC and
Electromagnetic Compatibility (EMC) Directive 2004/108/EC
Applicable Harmonized Standards:
TS EN ISO 12100–1 (2007), TS EN ISO 12100–2 (2006), TS EN ISO 13850 (2007),
TS EN 953 (1998), TS EN ISO 13849–1 (2007), TS EN 1088 (2005), TS EN ISO 60204–1
(2008)
Name : Fatih KAR
Position : Factory Manager
Signature :
Place-Date : SAKARYA / 17.04.2013

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WARRANTY CONDITIONS
The machine is under the warranty of KARMETAL LTD. ŞTİ. for a period of 2 years for
mechanical parts 1 year of electric and electronic parts from the date of purchase. This
warranty is subject to all of the terms and conditions listed below:
1. This warranty is valid only if the Warranty Registration Form is filled in and
returned to the manufacturer or its authorized dealer within two months after the
date of purchase.
2. The obligation of the manufacturer under this warranty shall be limited to repairing
or replacing components which proves defective and which our examination shall
disclose to our satisfaction to be defective.
3. Defects due to improper operation, misuse, neglect, alteration, irregular voltage
conditions, inadequate wiring, improper installation (all electrical and electronic
components, all electrical motors etc.) and due to accidents or any damage caused
by transportation, flood, fire, natural disasters, theft are not included in this
warranty and are strictly the responsibility of the purchaser.
4. Any part returned to KARMETAL or its authorized dealer under the terms of this
warranty shall be on the basis of transportation charges prepaid by the customer
and must be accompanied by a record of the machine model code and serial
number.
5. This warranty does not apply to the following components; band saw blade, blade
pressure pads or brackets and blade guide bearings because of being
consumables.
6. Manufacturer and authorized dealer cannot be blamed within maximum repair
period for the material or moral damage. Apart from that act the period as Warranty
Conditions and there will not be done any retroactive requirement.
KARMETAL SAN. & TIC. LTD. STI.
Dealer:

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Important!
This form must be duly completed and returned to the manufacturer or its authorized dealer
within two months after the date of purchase. Failure to do so will void the warranty.
WARRANTY REGISTRATION FORM
Machine Model : …………………………………………………………
Serial Number : …………………………………………………………
Invoice Date : …………………………………………………………
Invoice Number : …………………………………………………………
Dealer:
…………………………
Customer:
…………………………

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Contents
MACHINE CERTIFICATION AND IDENTIFICATION MARKING.............................. 2
ATTENTION!!!.................................................................................................................... 2
EC DECLARATION OF CONFORMITY .......................................................................... 3
WARRANTY CONDITIONS.............................................................................................. 4
WARRANTY REGISTRATION FORM............................................................................. 5
CHAPTER I : SAFETY................................................................................................ 7
1. Safety Rules .................................................................................................................. 7
2. Danger Zones on the Machine...................................................................................... 8
3. Safety Equipments and Assignments............................................................................ 9
4. Warning Labels and Assignments .............................................................................. 12
CHAPTER II : DESCRIPTION AND PROPERTIES ............................................... 13
1. Technical Properties of the Machine .......................................................................... 13
2. Standard Equipment.................................................................................................... 13
3. Optional Equipment.................................................................................................... 13
4. Noise Level................................................................................................................. 13
5. Machine Dimensions .................................................................................................. 14
6. Properties Table According to Metal Sawdust ........................................................... 15
7. KMT 280 WOS Bandsaw Machine Cutting Capacity................................................ 15
CHAPTER III : TRANSPORTATION AND INSTALLATION.................................. 16
1. Handling the Unpacked Machine................................................................................. 16
2. After Unpacking the Machine ..................................................................................... 16
3. Environmental Conditions.......................................................................................... 16
4. Shipping Brace............................................................................................................ 17
5. Machine Placement and Position................................................................................ 17
CHAPTER IV : PREPARATION BEFORE OPERATION ...................................... 18
1-Cleaning....................................................................................................................... 18
2- Removing the Shipping Brace .................................................................................... 18
3- Lubricating.................................................................................................................. 18
4- Hydraulic .................................................................................................................... 18
5- Coolant........................................................................................................................ 18
CHAPTER V: OPERATION.......................................................................................... 20
1- Control Panel.............................................................................................................. 20
2- Touch Panel................................................................................................................ 21
3- Machine Function/System Description ...................................................................... 31
CHAPTER VI: MAINTENANCE.................................................................................... 35
2- WEEKLY MAINTENANCE..................................................................................... 35
3- MONTHLY MAINTENANCE.................................................................................. 35
4- SIX-MONTHLY MAINTENANCE.................................................................... 35
5- PERIODIC MAINTENANCE .................................................................................. 35
CHAPTER VII: TROUBLESHOOTING......................................................................... 36
CHAPTER VIII: DISMANTLING................................................................................... 37
CHAPTER IX. SPARE PART LIST.................................................................................. 38
9.1. MACHINE BASE ASSEMBLY ............................................................................. 40
9.2. JOINT ASSEMBLY................................................................................................ 42
9.3. BOW ASSEMBLY.................................................................................................. 44
9.3.1 BRUSH COMPLETE............................................................................................ 46
9.4. BOW LIFT CYLINDER.......................................................................................... 48
9.5 GEARBOX ASSEMBLY......................................................................................... 52
9.6. BLADE TENSIONING ASSEMBLY..................................................................... 54
9.7. CLAMP ASSEMBLY ............................................................................................. 56
9.8. BLADE GUIDE ASSEMBLY ................................................................................ 71
9.9. ELECTRIC GROUP................................................................................................ 77

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CHAPTER I : SAFETY
1. Safety Rules
Never allow unqualified persons to operate or interfere with the machine.
It is important to develop personal safety awareness. Observe all related safety regulations
and pay attention for hazardous conditions. Discuss these conditions with your supervisor.
•You must use personal protective equipment, like safety glasses, gloves, safety work shoes.
•Do not remove warning signs and/or instruction plates off the machine.
•Do not open/remove any door or guard during operation.
•Make sure that all machine controls are set for the desired mode of operation, whenever
the setting of the machine control is changed, run the machine in slow mode to make sure it
operates as expected.
•Never disable any safety device to avoid its assigned function. These devices are intended
to protect both the machine and its operator.
•Do not load, unload, operate or adjust the machine without proper instructions.
•This machine is specifically designed for cutting general metal material. Do not cut wood
and analogous material, meat, fishery, food and agriculture products, combustible and
radioactive materials.
•Enough space should be provided around the machine to avoid hitting and provide a
convenient operation.
•Do not leave any tool on the machine after use. Do not put work stock or tools around the
machine, to avoid injury.
•Do not operate the machine with its safety guards removed.
•Do not wear gloves when operating through control panel.
•Wear gloves only when loading/unloading the material, changing the blade and chip brush.
•Never touch the blade, moving work stock, nor put your hands into the vice area or chip
conveyor unit until the machine halts completely.
•When selecting blade, blade speed and coolant, please refer to the operation manual or
related documents.
•Before installation and operate the machine check the sufficiency of the earth of the
machine to your electrician. Do not operate the machine without the earth.
•Determined and declared bench life of the machine by the Ministry of Industry and Trade
is 10 years.
•For longevity please follow the maintenance directions at the manual.
•For productive usage of energy and saw blade, use the recommended saw blade by the
PLC.

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2. Danger Zones on the Machine

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3. Safety Equipments and Assignments

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3.1. Cover Switch
This switch provides to shut down the machine while the bow cover is open. Running the
machine may cause wounding and serious gashes. Machine gives aural warning while the
cover is open.
3.2. Electrical Cabinet Cover Switch
This switch is used to stop the machine while the cover is open. Operating the machine
may causes to electric shocks while the electricity panel cover is open. Machine gives
aural warning while the cover is open
3.3. Upper Limit Switch
Upper limit switch is an adjustable switch and is used to adjust the bow’s apex to go rises
up.
3.4. Lower Limit Switch
This switch is used to adjust the bow’s nadir to goes down. Lower limit switch is a factory
setting. Please do not tinker with the lower limit switch.
3.5. Shuttle Vice Rear Limit Switch
This switch limits the motion to rear side of shuttle vice. When the shuttle vice touch to
this switch, it stops the movement of shuttle vice.
3.6. Shuttle Vice Front Limit Switch
This switch limits the motion to front side of shuttle vice. When the shuttle vice touch to
this switch, it stops the movement of shuttle vice.
3.7. Proximity Switch
A proximity switch is a sensor able to detect the presence of nearby objects without any
physical contact. In this machine proximity sensor detects that if the blade turning
somehow stops or reduces, it turns off the machine and save the blade life.