Mega BS-760M User manual

Semi-Auto BANDSAW
BS-760M
INSTRUCTION MANUAL
MEGA MACHINE CO., LTD.
DOC NO：BS760M-080410-100.U
CTRL NO：06
UPDATE：2008/4/11
DOC VER：A2

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TABLE OF CONTENTS
Item Contents Page
1. Introductory Illustrations 3
1.1. Principal parts 3
2. Specifications 4
2.1. Specifications 4
2.2. Standard Accessories 4
3. Installation 5
3.1. moving and lifting 5
3.2. Foundation layout and Set-up 6
4. Operation 8
4.1. Control Panel 8
4.2. Operating preparation 9
4.3. Manual Operation 10
4.4. Special Operation 10
4.5. Break -In Operation 11
5. Maintenance 12
5.1. Hydraulic Circuit 12
5.2. Oiling and Lubrication 13
5.3. Others 14
6. Trouble Shooting Guide - 16
7. Reference Charts 18
8. Attach Electrical Circuit

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FOREWORD
We hope that the owner of this heavy-duty bandsawing machine will have years of trouble-free
service. The machine has been built to the highest standards to enable fast accurate cutting to be obtained.
In order that the best results can be achieved from your MEGA band saw we would ask all operators
and maintenance engineers to READ THIS MANUAL CAREFULLY BEFORE STARTING
UP THE MACHINE. The manual contains full instructions on installation, operation, lubrication,
maintenance and trouble-shooting.
As MEGA MACHINE COMPANY LIMITED is constantly improving the design of its
machines, there may be some instance where this book differs somewhat from the machine with
which you are concerned. So, always quote the Serial Number of your machine, when ordering
spare parts or in correspondence relating to the machine.
MODEL : BS-760M
Serial Number :
Request for service and spare parts should be made to :
ADDRESS: NO. 180, INDUSTRIAL ROAD, TAI-PING CITY, 41107 TAICHUNG,
TAIWAN R. O. C.
E-MAIL: [email protected]; m[email protected]
http: www.bandsaw.com.tw
TEL: [phone](PRES.) FAX:[phone]

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1. INTRODUCTORY ILLU1STRATIONS
1.1 Principal Parts

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2 SPECIFICATIONS
2.1 SPECIFICATIONS
MODEL
PECIFICATION BS760M
CUTTING CAPACITY
AT 90
H BEAMS / PIPES
○SOLID 460 MM DIA.
□SOLID 460 SQR.
◎460 MM O.D.
□/ 760 x 400
MITRE CUTTING
AT 60°
H BEAMS / PIPES
○SOLID 420 MM DIA.
□SOLID 420 MM SQR.
◎460 MM DIA.
□/ 590 x 400 MM
MITRE CUTTING
AT 45°
H BEAMS / PIPES
○SOLID 330 MM DIA.
□SOLID 330 MM SQR.
◎460 MM DIA.
□/ 500 x 400 MM
MITRE CUTTING
AT 30°
H BEAMS / PIPES
○SOLID 220 MM DIA.
□SOLID 220 MM SQR.
◎220 MM DIA
□/ 220 x 400 MM
BLADE SIZE 38*1.3*5500 MM
1.5 x .051 x 209 IN
BLADE SPEED 25 - 80 M/MIN (50/60HZ) 25,32,42,55,70,80 MPM
82 - 260 F/MIN (50/60HZ) 82,105,138,180,230,260
MOTOR OUTPUT BLADE 7.5 HP (5.62 kW) HYD. 2 HP (1.5 kW)
CLNT 1/4 HP (0.19 kW)
SHIPPING VOLUMN 2805 x 2300 x 2100 MM
WEIGHT Net/Gross 2600 / 2900 KGS
Specifications subject to change without notice for improvement and modification.
2.2 STANDARD ACCESSORIES
1. Tools with tool box .............………….……..……....... 1 set
2. Band-cleaning wire brush ...…………………..….......... 1 pieces
3. Band saw blade .................…………………..……....... 1 piece
4. Instruction manual .............………………….……........ 1 copy

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3. INSTALLATION:
3.1 Moving and lifting:
Unpack your machine carefully, and use a crane or forklift to set it in position. If a crane is used to lift
the machine attach the lifting cable carefully to the machine as shown in the fig 2. If forklift is used
then fig 3.
Sufficient space should be left around the machine to allow safe handling of materials , and inspection
and maintenance operation. Should there be other machinery causing vibration or dust that near your
achine ,then precautions must be taken to keep your machine away from of vibration and dust.
(1) Use Crane :
Fig 2
(2) Use Forklift :
Fig 3

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3.2 Foundation layout and set-up:
(1) Foundation:
The foundation should be constructed of reinforced concrete and must be level and flat. After the proper
leveling position has been obtained, anchor the machine with anchor bolts. The position of anchor bolts
and floor dimensions are shown in fig 4:
□Contact portion with floor
○Position of anchor bolts
Fig. 4
※All leveling bolts should support the weight of the machine evenly .

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(2) Leveling:
The production accuracy of all precision machinery depends on the accuracy which the machine is
installed . Manufacturing tolerance of the machine can only be guaranteed if the machine is firmly and
properly installed . Once the machine is lowered on the prepared foundation . Machinist levels should be
Used alternately on the vise slide plates and the work feed table , and adjust the left-and-right and
fore-and-aft level of the machine with leveling bolt .
The fore-and-aft level should be adjusted so that the level of the rear end is approximately 10 mm (3/8" -
1/2") higher than the level of the front end , to provide proper return of the cutting fluid , and easy
operation of car feeding .
The left-and-right level should be adjusted so that the level of the left end is approximately 3 mm (1/8")
higher than the level of the right end , to provide proper return of the cutting fluid , After the proper
leveling position has been obtained anchor the machine with anchor bolts .
CAUTION : All leveling bolts should support the weight of the machine evenly .
Leveling as fig 5 below :
FIG 5
(3) Cleaning and oiling :
After the machine has been placed in position , thoroughly remove its rust preventive coating using a
suitable cleaning solvent and then apply a coat of machine oil . To clean the machine, Kerosene is
preferable to gasoline . It does not evaporate and level dried slushy compound on finished surfaces.
Rags are better than waste as they leave no lint or strings. The machine as received by you. has been
completely drained of all oil. Before any attempt is made to run it . Before any motor connections are
made .... every detail of the following oiling instruction must be complied with. Refer to the oiling chart
in chapter 7. Especially, don't forget to fill up the cutting fluid mixture. Usually, the ratio of cutting fluid
to water should be 1:30 - 1:50. Check the sight gauge to ascertain the fluid level in the tank every day.
Transmission gear box, bar feed gear box, hydraulic oil tank should to topped up monthly. Oil levels
should be strictly observed, for it is of primary importance for proper operation and long lift .
(4) Power Source Connection:
A. Power Source - This machine is equipped with 7.5HP main motor and 2HP hydraulic motor , and
1/8HP Coolant Pump. Connect the power supply cable to the circuit breaker(N.F.B.) terminals. The power
supply to your machine should agree with the wring voltage that is indicated on the label attached to the
electrical enclosure and main motor.
B. Earth - Be sure to connect the earth cable to the earth terminal.
C. Starting -After making the necessary wiring connections, turn the power switch on the control panel
clockwise to turn power on, depress the vise limit switch (if necessary, e.g. if there is no stock bar
clamped in the vise) and push the button to see if the saw head moves upward.
If the saw head does not rise , the hydraulic pump motor is rotating in the wrong direction.
If the motor runs in the wrong direction, turn off the power switch and disconnect the power supply cable,
Then interchange any two-phase connections.
Then interchange any two-phase connections.

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4. OPERATION
1. Control Panel
(1) Emergency Stop -- This switch is used for emergency case to stop the machine only.
Turn this switch clockwise makes power source on. When this
switch is pressed, all machine's operation stop immediately.
(2) Pilot Lamp -- This light will comes on when the power supply is on.
(3) Power Switch Off -- This switch is used for turning off the power by depressing it.
(4) Power Switch On -- This switch is used for turning on the power by depressing it.
(5) Quick Approach Button -- While this button is pressed, the saw head descends quickly.
This button is used to cause the saw blade to approach the work quickly when the saw blade is
at a distance frame the workpiece. When the feeler of the quick approach device comes into
contact with the work, the saw head stops descending at that position even this button is still pressed.
(6) Raise Button -- When this button is pressed, the saw blade motor stops and the saw head ascends.
The saw head stops ascending at that position when the button is released.
(7) A. Vise Open – Turn Left
B. Vise Clamp – Turn Right
(8) Blade Drive Button
(9) Clockwise angle Control Button
(10) Count Clockwise Angle Control Button
(11) Feed rate counter
(12) Work Beam Light switch

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4.2 OPERATING PREPARATION
There are several steps will be taken before start the machine.
(1) CHOOSE PROPER SAW BLADE :
Select the saw blade best suited to the workpiece to be cut, Size and shape of the workpiece , and
type of material should all be considered when selecting the saw blade to be used . There is a
reference chart in chapter 7 which can help you to select the right saw blade and cutting conditions .
(2) UNPACK THE SAW BLADE :
Usually the saw blade is packed in 3 circle ,unpack it one circle first grip the part to release another 2
circles gradually , tear off the saw-cap protective shield , inspect the blade teeth , make sure that the
cutting edge of the blade teeth point to the right . If they point to the left the blade should be turned
over.
(3) PLACE THE SAW BLADE ONTO BOTH THE DRIVEAND DRIVEN WHEELS ----
a. Turn the hydraulic blade tension handle clockwise , to fully loosen the driven wheel .
b. Open both the drive and driven wheel covers , place the saw blade onto both the drive and driven
wheels. Check the cutting edge of the saw blade , to ensure that it point to the right.
c. Insert the saw blade into both the left and right blade guides so that the back edge of the saw blade
touches the back-up roller of each guide .
d. The back edge of the saw blade should make contact with the flange of the drive and driven wheel ,
turn count -clockwise the hydraulic blade tension handle to tighten the saw blade , Then the blade
is properly tensioned .
e. Don't forget to tighten the insert adjusting screw .
(4) WORKPIECE CLAMPING :
a. Raise the saw frame , open the vise , place the workpiece on the roller table .
b. Gently push the workpiece into the roller-feed vise, taking care not hit the feed rollers.
c. Clamp the workpiece in vise.
(5) ADJUST THE BLADE GUIDEARM :
Properly position the blade guide arms according to the diameter (or the width) of the workpiece to be
cut.
a. loosen the insert adjusting screw.
b. loosen the lock lever of the blade guide arm, and manually move the blade guide arm to suit the width
of material using the scale provided.
c. After adjusting the blade guide arm position ,tighten the lock lever.
d. Finger tighten the insert adjusting screw.
(6) ADJUST THE POSITION OFTHE WIRE BRUSH :
a. loosen the lock lever of the wire brush case.
b. Manually move the wire brush case so that wire brush just contacts the cutting edge of the saw
blade.
c. Tighten the lock lever.
(7) ADJUST THE FEED RATE :
Select suitable feed rate for the workpiece to be cut. This varies according to the size and shape of the
workpiece, type of material , and what type of saw blade is being used. As a guide hard materials, wide
workpiece or structural sections and tubing have to be cut at a slower rate that mild steel bar.
As concerns the saw blade , high speed steel is better than carbon steel, and bi-metal alloy is better than
high speed steel. Roughly the ratio of feed speeds could be 1:2:3