KARMETAL KMT 400 KSA User manual

1
KMT 400 KSA
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!

3
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: D–100 Karayolu Uzeri Ayvalik Mevkii Hanli Adapazari / TURKEY
Phone: [phone] (3 lines)
Fax: [phone]
Web: www.karmetal.com.tr
E-mail: [email protected]
Machine type/model: KMT 400 KDG Semi Automatic Miter Bandsaw 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 / 25.03.2010

4
WARRANTY CONDITIONS
The machine is under the warranty of KARMETAL LTD. ŞTİ. For mechanical parts a period
of 2 years for electric and electronic arts a period of 1 year 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:

5
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:
…………………………

6
Contents:
MACHINE CERTIFICATION AND IDENTIFICATION MARKING ............................2
ATTENTION!!.........................................................................................................................2
EC DECLARATION OF CONFORMITY............................................................................3
WARRANTY CONDITIONS.................................................................................................4
WARRANTY REGISTRATION FORM...............................................................................5
BAND SAW USING INSTRUCTIONS ................ERROR! BOOKMARK NOT DEFINED.
CHAPTER 1: SAFETY .........................................................................................................8
1. SAFETY RULES .......................................................................................................................8
2. DANGER ZONES ON THE MACHINE .......................................................................................9
3. SAFETY EQUIPMENTS AND ASSIGNMENTS..........................................................................10
4. WARNING LABELS AND ASSIGNMENTS ...............................................................................12
CHAPTER II : DESCRIPTION AND PROPERTIES...............................................13
1. TECHNICAL PROPERTIES OF THE MACHINE.......................................................................13
2. STANDART EQUIPMENT .......................................................................................................13
3. OPTIONAL EQUIPMENT........................................................................................................13
4. NOISE LEVEL........................................................................................................................13
5. MACHINE DIMENSIONS........................................................................................................14
6. PROPERTIES TABLE ACCORDING TO METAL SAWDUST ....................................................14
7. KMT 350 KSA BAND SAW 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

7
CHAPTER V: OPERATION............................................................................................20
1- CONTROL PANEL ..............................................................................................................20
2- BLADE CHANGING PROCEDURE.......................................................................................21
CHAPTER VI: MAINTENANCE.....................................................................................24
1- DAILY MAINTENANCE...............................................................................................24
2- WEEKLY MAINTENANCE .........................................................................................24
3- MONTHLY MAINTENANCE ......................................................................................24
4- SIX-MONTHLY MAINTENANCE ..............................................................................24
5- PERIODIC MAINTENANCE .......................................................................................24
CHAPTER VII: TROUBLESHOOTING........................................................................25
CHAPTER VIII: DISMANTLING ...................................................................................26
CHAPTER IX: MACHINE FUNCTIONAL PARTS.......................................................27
1. CUPBOARD GROUP........................................................................................................28
2. VISE UNDERTRAY GROUP...........................................................................................29
3. JOINT FRAME GROUP...................................................................................................30
4. MOTION WITH HYDRAULIC VISE.............................................................................31
5. VISE GROUP......................................................................................................................32
6. GEARBOX GROUP...........................................................................................................35
7. HYDROMECHANIC BAND STRETCHING GROUP..................................................36
8. HYDRAULIC GROUP......................................................................................................37
9. COOLANT GROUP...........................................................................................................40
10. BANDSAW GUIDE GROUP...........................................................................................41
11. ELECTRICITY GROUP.................................................................................................42
12.SPRING GROUP...............................................................................................................49
13.BAND TENSION GROUP................................................................................................50
ASSEMBLY OF INFEED TABLE.......................................................................................51

8
CHAPTER 1: 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 vise 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.

9
2. Danger Zones on the Machine

10
3. Safety Equipments and Assignments