Toolots GB4232 User manual

Double-cylinder Horizontal Metal
Band Sawing Machine
Instruction Manual
Model：GB4232
Specification：12 19/32 inch
Serial No:

Warning
1. Never exceed the scope and application of the machine.
2. Never use machine before reading the Instruction Manual.
3.The operator must be trained professionally, having capacity to complete various
operations safely and to prevent the injury and damage by improper operation for the
machine.
4.Users must strictly follow the instruction manual for the correct installation and the
operation; provide appropriate and clean operational areas without any prejudice to the
operator for the safe operation and routine maintenance.
5. The operator must be regulated by the Instruction Manual and training requirements
and do maintenance for machine periodically to ensure the safety.
6.The operator must have security guards working conditions and regularly checks their
integrity, never arbitrary remove security guards. If necessary, protection-boom should
be set up around the machine.
7. Defensive cover must be covered all before operation and adjust saw blade
transferable protection as close as possible to the work piece. Never open any
protective mask during operation.
8.Check the machine stopped before replacing Band Saw and the round cocoon
protective masks and check whether the support firmly reliable. Protective gloves must
be carried to guard against the pricks and hurting when disassemble saw blade.
9. During operation, any part of the body never contact with the band saws or enter the
processing zones, never restock the jammed or cut off work piece.
10.Never operate or maintain running machine with gloves or loose clothing .
11.Before sawing, must confirm the work piece is clamped firmly, and to ensure that
the work piece at clamping state during the whole process of sawing; Do not loose the
work piece until saw blade stopped.
12.Enough support should be provide to long and heavy materials’ merging and cutting
to avoid the work piece drop in cutting , that may lead the cutting machine overturning.
Use feed and access information planes when cutting longer material.

13. Sure to cut off power before adjusting, repairing, maintenance and cleaning the
machine, especially in the maintenance of electrical, cut off power to prevent electric
shock accidents.
14.Machine must stop before varying speed.
15. Be sure the machine stopped when adjusting the distance of saw guide arm, and
fasten Hand Wheel after adjusting.
16.Machine power for three-phase alternating current, voltage fluctuations in the value
of less than 10%, Set up a separate power supply according to the rated capacity , Earth
leakage protection devices. Tt is prohibited to share wiring with the other equipment
which may cause voltage fluctuations or misuse.
17. Machine must completely on the ground, good and reliable.
18. If have any accident, please press the emergency stop button.
19. Cooling liquid may damage human skin, be careful when cleaning and operation. It
cannot drop into the underground, should be dealt with environmental requirements. To
prevent coolant splash in processing, users can set up protective railings plate.
20. In cutting chip combustible materials (such as magnesium, titanium, etc.), prohibit
pyrotechnics and should take fire measures.
21. Never sawing inflammable material in powder (such as carbon rod) to prevent fire
or explosion.
(Note: the technology date is subject to change.)

Table of Contents
ⅠMain application --------------------------------------------------------------------------1
ⅡMain Technical Data----------------------------------------------------------------------1
ⅢMachine Rigger and Installation-------------------------------------------------------1
ⅣMain Structures --------------------------------------------------------------------------2
ⅤElectric control system------------------------------------------------------------------4
ⅥHydraulic Transmission System-------------------------------------------------------7
ⅦLubrication System---------------------------------------------------------------------8
ⅧOperation System-----------------------------------------------------------------------9
ⅨMachine Tool Adjustment--------------------------------------------------------------10
ⅩTrouble Shooting and Obviates ways-------------------------------------------------15
ⅪAdd list ------------------------------------------------------------------------------------18
ⅫCommon Consumable Parts List------------------------------------------------------19

1
Ⅰ
Main Application
Band sawing machine is a continuous feeding equipment, mainly for the carbon steel,
low alloy steel, high-alloy steel, special alloy steel, stainless steel, acid-proof steel
and other metal materials. Can cut non-ferrous metals and non-metallic materials if
replace proper-able Saw Blades.
ⅡMain Technical Data
Form 1
Model
GB4232
Cutting Range(Inch)
Φ12 19/32 (W) 19 11/16x(H)12 19/32
Saw Blade Specification
LxWxH (Inch)
168 57/64 * 1 11/32 * 3/64
Cutting Speed (inch/min)
1023 5/8、1614 11/64、2047 1/4、2913 25/64
Voltage (V~HZ)
230V~60HZ
Main motor Power (kw)
3~4P
Hydraulic motor power (kw)
3/4
Cooling Pump Power (kw)
1/25
Fuel tank capacity (L)
40
Coolant volume (L)
30
Machine Dimensions LxWxH (Inch)
84 16/25x43 3/100x53 93/100
Ⅲ
Machine Rigger and Installation
1. Rigger
It should make full use of lifting equipment when handling machine, wire
connecting methods shown in Figure 1. Wood, rubber or other soft objects should be
used in the line of the vehicle-wire touching in order to avoid bumps machine and
painting. .
2.Box Opening
Check box when opening csuch as packing list indicating the volume of goods.
3.Installation

2
Machine should be installed in the place of no obvious source of shock, they can be
these concrete foundations. Machine surrounded should have adequate space and is
easy to install, debug and maintenance operations. Level on the jaw of the middle
position of the bed, see figure 2, along the vertical and horizontal adjustment band
sawing machine legs below the plane mattresses (customers to purchase) or Pad.
When the band sawing machine in level, sure to tighten bolts, see figure 2.
Figure 2 Forklift removal
Ⅳ
Main Structure
Base intracavity has more space, behind left is the Hydraulic Power Unit, and behind
right is the Power Supply Control Board. Hydraulic Pressure Oil Tank is on front left,
Coolant Box on front right. Lathe Bed and Bearing fixed at the base, the bed was
loaded with jaw, clamping screw and slip piece with the left Clamping Tank and
Handle Wheel. When Screw rotat the left jaw 10-25mm by the work piece, push tight
loose button to tight or unfasten work piece. Behind lean is be loaded with feeding
board, front leans be loaded with access material Board. Saw beams rotates around
the bearing with tension block and idler band wheel on the left; Worm box to its right.
The motor behind Worm box drives the worm and wheel which inside the worm box
Anchor Bolt
A- A

3
through four grade Pulley, triangular belt, Rotating round led initiative, and then
drive around the saw blade of driving band Wheel and Idle Band Wheel for cutting,
precision is adjusted by the Guide Arm and Guide Head and the hydraulic and
electric system controls the Saw cutting.
Machine tool isometric drawing
MotorMotor pulleypulley shieldshield
DrivingDriving baedbaed wheelwheel shieldshield
CollumCollum
SawSaw beambeam ScaleScale
DrivenDriven wheelwheel shieldshield
ControlControl panelpanel
OilOil tanktank cleaningcleaning covercover OilOil fillerfiller
LevelLevel gaugesgauges BaseBase mentment
ElectricElectric controlcontrol boxbox
SawSaw guideguide armarm

4
ⅤEleetric control system
5.1Main eleetric components schedule
NO
Name
Specification
Quantity
1
Transformer
BK-150VA 230V/27V/36V
1
2
ACcontactor
CJX1-12/22
4
3
Fuse gear
NXB-63Z C40
1
4
Fuse gear
NXB-63Z C6
3
5
Thermal relay
JR36-20(3.2-50)A
1
6
Thermal relay
JR36-20(6.8-11)A
1
7
Limit switch
YBLX19-001
6
8
Power switch
HZ5-20S4
1
9
Light
XDJ2-36V
1
10
Emergeney stop botton
LAY16-C01
1
11
Botton
LAY16AW22
1
12
Botton
LA16AW10
3
Botton
LA16AW11
4
5.2Saw machine control diagram figure
MainMain MotorMotor
CoolingCooling pumppump
ClampingClamping oiloil cylindercylinder
AuxiliaryAuxiliary columncolumn
TensionTension mechanismmechanism
LiftingLifting oiloil tenttent
SawSaw headhead
TurboTurbo boxbox
MachineMachine bedbed
ViseVise

5
Saw machine control diagram figure
M1 M2 M3
3~ 3~ 3~
QS
KM2
KM1
FR1 FR2
U V WWU
230V 60Hz
QF3
QF4
QF2 SB1
EL
KM3 SQ2
SQ1
KM4
KM4
KM3
KM3
2YV 3YV 4YV 5YV
KM1
KM3
FR2
FR1
KM1
KM2 KM3 KM4
SB2
Cooling motor Main m otor
Hydraulic motor
SB3 SB7
SB1
SB6
SB9
SB9
SB8
SB3
PE DB-12A 40W
HL
U1 V1 W1W2
V2
U2
QF1
BK-150VA VC
6.8-11A
3.2-5A
KM4
KM1
3Kw 1440r/min 0.75kw
1400r/min
1YV
SB7 KM1
Powe r s w i to h
UP Fasten Release
Down
Ru n ni n g o il pu m p r u n Faste nUp
Fuse gear
Mai n frame co oling pump Oil pump Control
transformer
Mainframe
norking
L3
L2
L1
230V
36V 27V
24V
SB4
SB5 KM2
SQ3 SQ4 SQ5 SQ6
S B1:Emergen cy stop SB 2:stop SB3:Running SB4:Oil pump stop SB 5:Oil pump run SB6:U p S B7:Down SB8:Fasten S B9:Release

6
Electrical device of saw machine
Note:IfNote:If techinicaltechinical datedate subjectsubject toto change,referchange,refer toto thethe realityreality
230V230V 60HZ60HZ
WV
U
PEPE
230V230V 60HZ60HZ
PEPE
PEPE
PEPE
L
L
2121
2222
0
1
27V27V
2626252524242323 W2W2V2V2U2U2
1
2
DireetDireet currentcurrent outout 24V24V
AlternatingAlternating currentcurrent inputinput 27V27V
2222
3030
2020
2828
KM3KM3 KM2KM2 KM4KM4
MainMain motormotorOilOil pumppump motormotor
RiseRise andand fallfall
CJx1-12/22CJx1-12/22
CJx1-12/22CJx1-12/22
CJx1-12/22CJx1-12/22
QSQS
QF1QF1
36V36V
0.75KW0.75KW
OilOil pumppump motormotor
BK-150VABK-150VA
FastenFasten
UpUp
DownDown
ThrottleThrottle
EmergencyEmergency stopstop
SignalSignal lightlight
SQ2SQ2
SQ1SQ1
LowestLowest limitlimit switchswitch
10109
HighestHighest limitlimit switchswitch
1111
1010
WorkingWorking lightlight
40W40W
36V36V 02
3030
2727
3030
2323
3030
2424
32
20
W2W2V2V2
U2U2
W1W1V1V1U1U13030
232324242727282820
L1L1 L2L2 L3L3
00
0
72828
2929
98
2828
2828
2323
2727
1010 1010
1111
2828
4
9
1111
2424
W
V
U
W
VU
U2U2 V2V2 W2W2 U1U1 V1V1 W1W1
U2U2 V2V2 W2W2 U1U1 V1V1 W1W1
341010 1111
5A5A 11A11A
W2W2V2V2
U2U2 U1U1 V1V1 W1W1
QF1QF1
UVW
C40C40
6A6A
3 4 101091111
RunningRunning
StopStop
7
3
7
5
8
7
UpUp
1010
9
DownDown
2727
2828
9
5
24242828
2626 2525
2525
3030
2626
3030
FastenFasten ReleaseRelease
1414
OpenOpen thethe dooranddoorand powerpower offoff
FastenFasten
1616
1515
ReleaseRelease
2828
1515
2626
3
L1L1 L2L2 L3L3 U2U2 V2V2 W2W2 U1U1 V1V1 W1W1 U1U1 V1V1 W1W1
PowerPower lineline OilOil pumppump MainMain motormotor CoolingCooling motormotor
2121
2222
QF3QF3 6A6A
KM4KM4
ClampClamp loosenloosen
CJx1-1210CJx1-1210
0
1515
8
2828
9
2525
1616
1616
OilOil pumppump runrun
3434
3333
OilOil pumppump stopstop
3333
2
3333 3434
3333
3434
0101
1
0101
QF2QF2 6A6A
AlternatingAlternating currentcurrent inputinput 27V27V
DireetDireet currentcurrent outout 24V24V
SQ3SQ3 SQ4SQ4 SQ5SQ5 SQ6SQ6
SecuritySecurity
777771212 1313
0:36Vnull0:36Vnull lineline 01:work01:work lightlight
2:Signal2:Signal lamplamp 33:oil33:oil pumppump lockinglocking
34:oil34:oil pumppump workingworking 3:run3:run thethe locklock
4:main4:main motormotor runningrunning 7-77:desigh7-77:desigh schemescheme
9:down9:down limitlimit 10:rising10:rising lockinglocking 11:rising11:rising
limitlimit
12:fasten12:fasten 13:release13:release 28:24Vcontrol28:24Vcontrol busbus
27:DCfastdrop27:DCfastdrop 26:DCrelease26:DCrelease 25:DCfasten25:DCfasten
24:DCdown24:DCdown 23:DCrise23:DCrise 30:DCnull30:DCnull lineline
7
7777

7
ⅥHydraulic Transmission System
6.1Main hydraulic components schedule
NO
Name
Spectfication
Quantity
1
Filter
HY-37
1
2
Vane opump
YB1-4
1
3
Relief valve
P-B10B
1
4
Pressure gauge
YNT-60
1
5
Three-positionfour-way
solenoid valve
4WE6E/60EC24
1
6
Three-positionfour-way
solenoid valve
4WE6E/60EC24
1
7
Clamping tank
Φ80x500
1
8
Lift tank
Φ80x350
1
9
Two-position two way
solenoid valve
4WE6D/60EC24
1
10
Throttle
L-10
1
6.2Hydraulic system diagram
TightenTighten
LoosenLoosen UpUp
DownDown
2YV2YV1YV1YV 4YV4YV3YV3YV
5YV5YV
1
2
6
4
5
7 8
3
9
1010

8
ⅦLubrication system
7.1Lubrication System
1.Must refuel according to requirements of Figure7and Table 6 before start the
machine
2.Lubrication for the worm gear box: use the 30th oil to bath the box; the oil inside
the box is about 1 kg. Oil is plug into the Worm boxes from the top hole. Oil is on the
side of the box, when sawing beams at the lowest position; the Oil surface should
between the superscript. Change the oil a month after for the fist time use, after that,
changes oil each 3-6 months. There is a oil bolts in the lower worm gear box. The
bottom of Machine Box fixed with hydraulic oil and coolant oil Cypriots.
Lubrication point diagram
7.2Saw band lubrication site form

9
NO
Lubrication site
Oil varieties
Lubrication Interval
1
Tension movement and
screw
Lubricant
Once a month
2
Auxiliary column
Lubricant
Once a week
3
Machine bed slideway
Lubricant
Once a week
4
Turbo box
30#Gear oil
According to actual condition
5
Collum
Lubricant
Once every 15days
6
Beam guide
Lubricant
Once every 3months
7
Driven wheel
Grease
Once every 6 months
ⅧOperation system
Operation panel
1.Control panel composition and function
(1) Press the "EMERGENCY STOP" buttons, cutting off power supply, rotate
clockwise direction, mushroom handle outward increased, connect control power; If
the pressure pushed inward, mushrooms handle inward compression, disconnect
power control.
(2) Press the "RUNNING" button, the main motor running take the saw blade rotary,
and pumps work, to achieve the cooling cycle. If "Clamp up" button not pressed, the
control can only done by man. Press the "stop" button to stop the mainframe and
pump.
(3) Press “OIL PUMP”button , Oil Pump and Hydraulic System start to work.
STEPLESS SPEED CONTROL
EMERGENCY STOP
SIGNAL LIGHT OIL PUMP RUN
OIL PUMP STOP
RUNNING
STO P DOW N
UP
FASTEN
RELEASE
0
1
2
3
4
5
6
7
8
9
10
Do Not Hit Panel Area

1
0
Push “STOP”, stop working.
(4) Press “UP”button , the mainframe stops, Saw Bean lift till touch the
High-limit Switch. Press “DOWN”button , Saw Bean falls.
(5) Press the "FASTEN" button, the vise clamping
(6) Press the "RELEASE" button then vise loose.
(7) When rotate "STEPLESS SPEED CONTROL" knobs by clockwise direction,
the feed speed Increase, counterclockwise rotation makes speed slow down and
finally stop.
(8) When one of the safety shields is not closed and the saw blade is broken,the
machine will be powered off and cannot be started.
2.Other operation agencies
Length of Work piece controls the block
Adjust the lock nut on the locating rod to determine relative position between one
point of the work piece and saw blade cut.
ⅨMachineTool adjustment
1 Place the machine on the no vibration ground to check whether the machine intact,
and clean machine with antirust oil.
2 As shown in Figure 4, introduce four wire three phase to the wiring board on
electrical box from outside. Open the blinds of hydraulic oil and fill hydraulic oil 46#,
unto the surface of Filter. Connect the power supply, instruction light is on, and rotate
emergency stop button by clockwise to connect the control power, and press the

1
1
pumps work button to start the Hydraulic system. Then push the “up”button,
sawing beam increase; push “down”button, sawing beam drops. Repeat for several
times to make sure there is no air rose and drop steadily.
3.Saw Blade Installation
(1).Unfold the new saw blade, be careful and pay attention to avoid collision teeth.
(2).Push the "up" button; adjust the width of Guide arm, wider than that of the work
piece of 30-50mm.
(3).Open the cover of the Drive Band wheel and Idler Band wheel.
(4). Loosen the copper wire brush to lower it.
(5). Install the saw blade to a Drive Band wheel and Idler Band wheel and make the
serrated downward.
(6). Insert saw blade to the middle of left and right guide head, and fit the alloy
block on the sawing back.
(7).Let the back edge of saw blade forward to the flange of Drive Band wheel and
Idler Band wheel, and keep its flange and the gap to 1-2mm. See Figure 13.
(8). Inspect vertical between the face of the clamping vise and the side of the saw
blade with square, acceptable tolerances is 0.2/200.
(9). When adjust the saw blade Tension, must tension band appropriately to ensure
normal sawing. If tension is too large, saw blade would fracture easily; if tension is
too small will lead to slip easily even fight tooth. Tension is determined by the
material and size of the work piece, and generally 25-35N.m. The project should be
completed more than 2-3 times, never to tension One-off or the saw blade may force
unevenly. (Note: after work, loosen the saw blade to avoid premature fatigue).

1
2
(10). Tighten the left and right adjustment bolts to compress the alloy block and saw
blade.
(11). Adjust the location of copper wire brush to make it contact with saw tooth, see
the position in Chart 10. When the copper wire brushes worn, adjust any time and
finally fastening bolts.
Figure 10
(12).The Deviation adjustment of Idler Band wheel. The axle centerline of Idler Band
wheel is not vertical to saw blade movement direction. When the Saw Blade is not in
tension, requires the direction of axle center line of Idler Band wheel,which is
perpendicular to the movement of the saw blade, oblique to the left 0.5 °-0.8 °,
see figure 12. This can avoid the saw blade down from the outer edge of Idler Band
wheel, when the saw blade is running, which may lead to saw swap. If the swap
occurred, must adjust the deviation of the Idler Band wheel. Adjusted as follows:
First, take the plane of Drive Band wheel as reference, adjust the first two screws of
Tension Block, which is behind the Idler Band wheel bean, see figure 12. Adjust the
parallelism of Drive Band wheel and Idler Band wheel. (Way of check: put two
plywood with the size of 35 cm x 35 cm on the top of two wheels, check them if
parallelism), then adjust another screw, see figure 13. Do the declination adjustment

1
3
(redeployment saw blade to cut back with a
round-edge line from the 1-mm air for good) see figure 12, and then tighten the 3
screws to prevent loosening.
Figure 11 Figure 12
(13). Cover the Drive Band wheel and Idler Band wheel.
(14). The choice of saw blade speed
Saw blade speed is adjustable four grades, 1023 5/8、1614 11/64、2047 1/4、2913 25/64 , see
the reference in Table 7 and 8. Chose suitable cutting speed according to the material
and nature of work piece. In order to upgrade the saw blade life, may choose to use
low 1-2 stalls cutting speed.
4. transform saw blade speed:
(1).Turn off the power switch, open wheel cover.
(2).Loosen locking nut of Motor Block.
(3).Selected the cutting speed, and exchange the location of texrope.
Tension Block
Bean Board
Driven Gear
Deviation Adjustment Screw
Tension Block
Hexagon Socket-head
Hollow Bolt
Bean Board
Driven Gear
0.5-0.8°
Cap Screws
Space of Blode Baoke
and Sawing Wheel Plane1-2mm
Fixed Vise
L-Square Saw Blade

1
4
(4).Tight locking nut of Motor Block.
(5). Cover the Pulley
5. The cutting efficiency of easy cutting materials is usually, cut hard materials
should be lower. For example: take the iron as describing, if the iron in thin or
powder, they should increase the cutting speed; and if the iron is charred and thick,
should lower the cutting speed. The iron should be in roll with the correct cutting
speed, see figure 16.
6. The new Blade "running-in"
New saw blade must be carried out "running-in" before starting cutting; Otherwise,
they would shorten the life and become not effective cutting.
7. Provisions of Bundle cutting.
When in buddle cutting, " the hydraulic compactor”(Customers purchase by
themselves) should be installed, which is the device compress with the clamping Vise.
Chart 13.
Figure 13
Press Device
Increase Cutting Rate
Sawing Direction
Speed Direction
Powder or thin Scrap iron
Speed and Cutting rate right
Scrap iron in roll
Speed Direction
Sawing Direction
Decrease speed and Cutting Rate
Charred thick Scrap iron
Sawing Direction
Speed Direction

1
5
Ⅹ
Trouble Shooting and Obviation
NO.
ITEM
CAUSE
SWEEP MATHOD
1
Saw
blade
tooth
broken
1.Wheel edge cab the flange of saw
blade
Adjust the skateboard of
guide arm or tension
structure to set a gap
between saw blade back and
the wheel flange in running.
2. Irregular
Work piece shape
Adjust Profile to make the
contact surface as wide as
possible, so as to ensure
clamping firmly.
3. Saw overload
Reduce the feed speed
4. Saw blade loosen
Tension the saw blade
5.Chip accumulate in Guide Block
Remove and clean the Guide
Block
6. Improper Saw blade
Chose Saw blade according
to material of woe piece
7.Saw blade speed too slow
Accelerate the speed
8.Insufficient ubrication
Increased the quantity adjust
lubrication site
9Hydraulicoilshortage
Add Hydraulic oil 46#

1
6
NO.
ITEM
CAUSE
SWEEP MATHOD
2
1.Speed
instability,
feed speed
too slow and
small
adjustment
range
Impurities plug valve Oil
Pipeline
A.Remove and clean the
Speed valve then re-install
B.Check the fuel quality,
replace it when necessary
2.Feed
excessive
speed
Speed valve damaged, press
between the valves not
enough
Clean the Speed valve with
diesel
3.Lift
Cylinder
leakage
Seal damage
Change seal
3
Swap Saw
Blade
1.The plane of Two guide
arms is not on the exterior
common tangents of Two
saw wheels
Adjust Guide arm
2.If this method ineffective，
adjust Tension Block
location，see Figure 12
Adjust left screw of
skateboard.Loose with a
wrench, then tighten it to the
direction of saw blade edge
with sleeve clockwise.
4
Sawing
Accuracy
1. The planes of Saw blade
and clamping vise are not in
vertical aspect
As above
2. Saw Blade wear
Blade replacement
3.Excessive Feeding speed
Reduce the feed rate
4.Guide Arm loosen
Tighten Guide Arm
5.Excessive Two Guide Arm
space
Reduce the space