KBC BAH-1010AVS User manual

MACHINERY DIVlSlON
5465 16 MIL.F ROAD
STERLING HEIGHTS, MI 4831 4
PHONE:
(536) 731 -36CO 1-800-860-1 740
<g{jJ@*&$m;im# MX:
----
?i
(586) 731 -3464 * 1 -800-862-1 740
MODEL BAH-IOIOAVS
BANDSAW
THANK YOU FOR PURCHASINGWlTH KBC MACHINERY. ALL KBC
MACHINESARE BACKED BY OUR
1 YEAR PARTS REPLACEMENT
WARRANTY. WHEN USED AS INTENDED, AND WlTH PROPER
MAINTENANCE THIS MACHINEWILL PROVIDEYOU WlTH YEARS OF
TROUBLE-FREESERVICE. IFYOU NEED PARTS SIMPLY FILL OUT
THE PARTS REQUEST FORM, AND FAXOR E-MAILYOUR REQUEST.
ALL OTHER QUESTIONS PLEASECONTACT US
@ :
KBC MACHINERY
6465 18 MILE ROAD
STERLING HEIGHTS,MI
48314
PH [phone]
FAX [phone]
www. KBCTOOLS. COM

Instruction Manual
AutomaticHorizontal

I
NOTICE: Please read this instruction manual carefully to obtain a
thorough knowledge of installation, operation and maintenance. Please
remember the following: Correctly operatethe machine asdescribed in the
manual to prevent accident. Do not operate the machine by guesswork. We
suggest you always keep manual athand and refer to
it whenever you are I
I
not sureof how to perform any procedures for AH-101OJAY.
I
Instruction Manual:
AH-lO1OJAY HorizontalBandsaw
Ver. 2 -- Date : 1211711998

FROM THE MANCJFACTURER
You havejust purchased a machine manufactured by the COSEN Machinery
Industrial Co., Ltd. We'd like to take this chance to express our appreciation to you for
being our valued customer. Any comment From you will help us to design a better
product or provide a better servicefor you.
Theband sawmachine will provide low cost cutting accuracy for many years ifthe
procedures for installation, operation, maintenance and troubleshooting are followed.
However, if there are questions, please contact our agent or our factory for the nearest
, service or sales representative.
Enough, already.
I hope you find COSEN as incredibly smart as I do. If you have
any suggestionsfor improvement, please tell us, we
will appreciate your help.
"again"
Thank you so much for purchasing
COSEN band sawmachine.
President
\
R
COSEN Machinery Indus ial Co., Ltd.

YC2 Richard is nynam: Taadirgis nygane
Bmenithm: Andbeapofessw.

SAFETY
-
1. Know your band saw. Read the operator's manual carefully. Learn the operation, applicationand
limitation. Realizethe specificpotentialhazardspeculiarto this band saw.
-
2. Use recommended accessories.Improper accessories may be hazardous.
3. Wear proper apparel.
4. Keepunnecessarypeople away.
* Do not overreachor stand on tool.
-
5. Avoid dangerous environment. Do not use band saw in damp or wet locations. Keep work area
well illuminated.
-
6. Keep work area clean. Clutteredand slippery floors invite accidents.
7. Remove adjusting keys and wrenches from band saw before turning on power.
8. Avoid accidental starting. Make sure switch isoffbefore plugging inpower cord.
-
9. Do not force band saw.It is safer to operatewith the cutting rate for which it was designed.
10. Never hand hold the material with saw in horizontal position. Always use the vise, and clamp
-
secure1y.
11. Keepbelt guard and wheel covers in place and in working order.
12. When a workpiece is too long or heavy, support it fromthe floor.
13. Always remember to switch offthe machine when the work is completed.
14. Disconnectpower cord before adjusting, servicing and changingblade.
15. Check damaged parts. Before further use of the tool, a guard or other parts that is damaged should
-
be carefullychecked.To assurethat it will operateproperly and perform its intended function.
16. Moving parts should keep in an alignment and binding. Check for breakage, mounting and any
other conditions that may affect its operation. Any damaged part or guard should
be properly
. -
repaired or replaced.
17. Use a sharpblade andkeep tool clean for best and safestperformance.
-.
18. Safety is a combination of operator's common sense and alertness at all times when the saw is
functioning.
19. Maintainingthe band sawin top condition is essentialfor safety.

SAFETYRULES
Never wear gloves loose clothing when operating the machine. They may cause danger if they are
caught
in a runningmachine.
Be sure to
confi that the area around the machine is cleared of people and obstaclesevery time
before startingthe machine or operation.
I Use a water-soluble cutting fluid onthis machine. Oil-based cutting fluidsmay emit smoke or catch 1
.
fue, depending onthe conditionof their use.

W Never try to adjustthe wire brush on the saw bladeor remove chips when the saw blade is running.
It
is dangerousif hands or clothing are caught by the running blade.
W Never cut carbon or any other material that produces and dispersesexplosive dust on this machine.
Sparks
from motors and other machine parts may ignite and explode the air-borne dust The machine
needs specialmeasures for cuttingexplosivematerials.
Stop the saw blade before you clean the machine. It is dangerous if hands or clothing are caught by
the
running blade.

---- SAFETY RWES
Be sure to prohibit any use of fire in the shop, and install a fire-extinguisheror other fire control
device near the machine when cutting titanium, magnesium, or any other material that produces
flammablechips.Never operatethe machine unattended when cutting flammablematerials.
Use roller tables on both front and rear sides of the machine when cutting the long work. It is
dangerous if the work falls off the machine when the roller tables are
not used.
Take preventive measures when cutting thin or short pieces from the work to keep them
from
falling. It is dangerous if the cut piece falls.

SAFETY RULES
Neverstart the saw blade unless it has been confiedthat the work is fumly clamped. If thework
is not securely clamped with the vise, pieces will be forced out of the vise during cutting.
w
Never touch the running saw blade. It is dangerous if your hands or clothing are caught by the
running blade.
Never step orstandon the roller table. It is dangerousif your foot slipson the rollersand you fall.

SAFETYRWES
0
Turn off the shop circuit breaker switch before servicing the machine. Then post a sign to inform
people
that the machine is under maintenance.

Emotion
Foreward
Safety Rules
Section
1 GENERAL INFORMATION 1-1 - 1-5
1.1 INTRODUCTION 1-1
1.2 EQUIPMENTDESCRIPTION 1-2
1.3 SPECIFICATIONS 1-3
1.4 IDENTIFICATION AND TERMINOLOGYOF THE MACHINE 1-4
1.5 SYFETY DEVICES AND SAFETY GUARDS 1-6
1.6
NOISE LEVEL 1-8
2. MOVINGAND INSTALLATION 2-1 - 2-5
2.1 INTRODUCTION 2-1
2.2 MOVING OF THE MACHINE 2-1
2.3 INSTALLATIONOF THE MACHINE 2-4
2.4 WORKING CONDITIONS 2-10
3. OPERATING INSTRUCTION 3-1 -3-12
3.1 SAFETYPRECAUTIONS 3-1
3.2 PREPARATIONFOR USE 3-2
3.3 CONTROLPANEL 3-3
3.4 CHECKLISTBEFORE OPERATING 3-15
3.5 HOW TOLOAD THE WORKPIECE 3-15
3.6
TEST RUN THEMCHINE 3-16
3.7
HOW TO SELECT AND REPLACETHE SAWBLADE 3-18
3.8
PROCEDURESTO STOPAN OPERATING PROCESS 3-21
4. ELECTRICAL SYSTEM 4-1 - 4-2
5. HYDRAULICSYSTEM 5-1 - 5-2

5.1 INTRODUCTION 5- I
5.2 THEHYDRAULIC CIRCUIT 52
5.3 THE LAYOUT OF THE HYDRAULIC SYSTEM 5-3
6. BAND SAW CUTTING-APRACTICALGUIDE 6-1 -6-5
6.1 INTRODUCTION 6- 1
6.2 BAM) SAW BLADE SELECTION 6-1
6.3 SOMESAWINGPRACTICES 6-3
7. MAINTENANCE 7-1 - 7-3
7.1 MAINTENANCE SCHEDULE 7- 1
7.2 STORAGECONDITIONSOF THE MACHINE 7-2
7.3 DISPOSAL OF THE MACHINE 7-2
8. SYSTEMSTROUBLESHOOTING
8-1 -8-4
8.1 INTRODUCTION 8- I
8.2 GENERAL TROUBLESAND SOLUTIONS 8-2
8.3 MOTOR TROUBLESAND SOLUTIONS 8-3
8.4 BLADE TROUBLES AND SOLUTIONS 8-4
9. PARTS LIST 9-1 - 9-11
CHART 1 SAW BOW
9- I
CHART 2 BLADE GUIDE ARMS
9-4
CHART 3 BED ASSEMBLY 9-6
CHART 4 BASE ASSEMBL 9-8
CHART 5 HYDRAULICSYSTEM 9-II
APPENDIX
A. Specificationsof theMachine . appendk- I
B. FoundationDiagram appendii- I1
C. Accessories of theMachine appendix-ID
D. MaintenanceSchedule appendix-N

GENERAL INFORMATION
Section 1
SECTION 1
GENERAL INFORMATION
1.1 INTRODUCTION
COSEN is one ofthe bandsaw makers who have manufacturedthe machines for more than
two decades and COSEN is devoted to the research and development of advanced technology to
improvethe qualityand safety of bandsaws.
Almost all of the countrieslay emphasisonthe safety design concept inorder to envisage
the coming next century.
As a machinery industrial company, COSEN continues to follow this
central concept of excluding all sources of possible injury or damage to health ffom bandsaw
operation.
~owevei,the customer's confidence depends not only on the quality of the products and
the reputationof themarket but alsothe certificationof a notified body, although COSENbelieved that
the formertwo terms
had been well achieved for herproducts.
Recently one thing happened and it could
be considered as a greatmilestone for COSEN
to get into the-state-of-the-arttechnology, that
was, after the outsideassistanceof a notifiedbody,
AMTRI VERITAS Limited,COSEN had obtainedthe CEDESIGNATION, a national standard
which was approvedby ECS (European Committee for Standardization).
COSEN metal cuttingbandsaw is an idealtool forthe machine shop, metal fabricating
shop, schooland limited
run production work.
Your machineisdesigned to cut the metalmaterialsand possessesthe followingadvantages,
Machinery or each componentcan be handled safely.
Machinery or eachcomponentcan be easily removed, replaced or operated
by the user.
Machinery or each componenthas passed the strictlytesting (CouncilDirective on the
approximationof the laws of the Member Statesrelating to Mach'iety)
Thismanual is divided into ten sections including shipping, handling,unpacking,
initial checkout, operation, and maintenance.Each section covers a specificaspect of the machine.

GENERAL INFORMATION
Section 1
.
1.2 EQUIPMENT DESCRIPTION
Your machine is designed under the guideline of low cost and high performance. The features are
describedbelow,
Straightcutting with easy set-upand high precision positioning.
-
Heavy duty motor, rigid reducerand variabledrive assemblywith excellent mechanical
designfeature the increasing demand for productioncutting.
Also applicable for structural steel processing, such as pipe, channel, H beam, angle and
bar stock with automaticroller feeding.
Amply-dimensioned machine base and sawframe allowseasy operating.
CentralizedKnee-typefront controlbox (mainelectrical box).
-
The blade guidance mounted with bearings and carbidefaced insertsmaintains
the stabilityof machining and reducesthe vibrations of cutting. Thisproduceshigh
degree of cutting accuracyand a long blade life.
.-
The cast iron dovetail slideguideand guidearms constructtheunique characteristics
of rigidity and stability.
This machine isdesigned to preventthe operator from accidentalaccessto moving
elementsduring operationby using safety
guards.
If the saw blade isbroken during the cutting period, the machine will stop automatically.
The life of the machine is approximately 10 years if it is operated under normal
operatingconditionsand maintenance,
8 hours X 5 days X 52 weeks X 10 years = 20,800 hours

Lp- c GENERAL INE'ORMATION
Section 1
1.3 SPECIFICATIONS
SPECIFICATION
MAX. CAPACITY 250 mn (10")
250 B X 250 W (10" X 10")
60 Hz 29,46,65,98 (&in.)
CUTTING
SPEED RANGE
ELECTRIC SYSTEM
COlPLETE COOLANT ONE UNIT
* Design and specificationsare subjected to change without notice.

1 - A GENERAL INFORMATION
Section 1
1.4 IDENTIFICATIONAND TERMLNOLOGYOF THE MACHINE
A. Dovetail SlideGuide
B. Drive Wheel Cover
C. Ann Fixing Handle
D. ElectricalBox and ControlPanel
E. Dovetail Gauge Plate
F. Stopper
FRONT VIEW

1. -- A GENERAL INFORMATION
Section 1
G. FixedVise Jaw
H. Movable Vise Jaw
I. Motor
J. Pulley Cover
K. Hydraulic Feed Cylinder
L. Blade TensionAdjustment Handle
M. Idle Wheel TensionAdjustment Slide
N. Bed
REAR VIEW