YILMAZ MK 420 User manual

Ylmaz PVCveAlm. İşleme MakineleriLtd.Ştd
MK420
1
MK420
MANUELALTTANÇIKMAKESMEMAK NES
MANUELCUTTINGMACHINES WITHHIDDENSAW
USERMANUAL-KULLANIMKLAVUZU
01-07

Ylmaz PVCveAlm. İşleme MakineleriLtd.Ştd
MK420
2
GARANT
İMALATÇIFİRMAUNVANI :YILMAZPVCveALÜMİNYUM İŞLEMEMAKİNELERİSAN.TİC.LTD. ŞTİ
ADRES :TURGUTÖZALBULVARI NO:173 TAŞDELEN34788 /ÇEKMEKÖY
İSTANBUL-TÜRKİYE
TELEFON :[phone] PBX
TELEFAX :0216 484 42 88
FİRMAYETKİLİSİNİN
İMZASIve KAŞESİ:
MALINCİNSİ:MANUELALTTANÇIKMAKESMEMAKİNESİ
MARKASI :YILMAZ
MODELİ:MK420
BANDROLveSERİNo :
TESLİMTARİHİveYERİ:
GARANTİSÜRESİ:2YIL
AZAMİTAMİRSÜRESİ:30 İŞ GÜNÜ
YETKİLİSATICIFİRMANIN
UNVANI:
ADRESİ:
TELEFONU :
TELEFAX:
TARİH– İMZA–KAŞE :

Ylmaz PVCveAlm. İşleme MakineleriLtd.Ştd
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ENGLISH
CONTENTS
1.GeneralInformation
1.1.Introduction
1.2.Informationaboutthemanufacturer
2.Machine’sDescriptionandPurposeofUse
2.1.Machine’sdescription
2.2.Technicalfeatures
2.3. Cutting diagram
2.4.Overall dimensions
2.5.Partlist
3.Safety
3.1.Safetyinformation
3.2.Accidentprevention
3.3.Generalsafetyinformation
4.Transportofthemachine
5.Installationofthemachine
6.Machinesafetyinformation
7.Operation
7.1.Cutting operation
7.2.Slice operation
7.3.Changing thesaw
7.4. Angularadjusmentandcorrectness controlofsawbladeandsetsquare
7.5.Adjustofbelt tension
8.Maintenance, Service andRepair
8.1.Starting work
8.2.Maintenanceattheendofworkingday
9.TroubleshootingGuide

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TurgutÖzalBulvar No173Taşdelen34788
Çekmeköy/ ISTANBUL-TÜRKİYE
Tel: [phone] Pbx
Fax: [phone]
e-mail [e-mail]
web http://www.yilmazmachine.com.tr
1.GENERALINFORMATION
1.1.INTRODUCTION
Theuser’smanualgivenbythemanufacturercontains necessaryinformationaboutthemachineparts.Eachmachine
operatorshouldreadtheseinstructionscarefully,andthemachineshouldbeoperatedafterfullyunderstanding them.
Safeandefficientuseofthemachineforlongtermdependsonunderstanding andfollowing theinstructionscontained
inthismanual.Thetechnicaldrawingsanddetailscontainedinthismanualconstituteaguidefortheoperator.
1.2.MANUFACTURER
*IncaseofanytechnicalproblempleasecontactyournearestYILMAZdealer,orYILMAZheadoffice through the
abovementionedphone, faxore-mailaddress.
*Technicallabelswiththemodeldescriptionofthemachinearefixedontothefrontsideofeachmachine.
*Themachine’sserialnumberandmanufacturing yeararestipulatedonthetechnicallabel.
Averagelifeusageofproductionis10years. Ifyouhaveanyfurtherfailure andcomplaint,pleaseinformto
ourbelowmentionedtechnicalservice byverbalorwritten

Ylmaz PVCveAlm. İşleme MakineleriLtd.Ştd
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TECHNICALSERVICEADDRESS;
TurgutOzalBulvarıNo173 TASDELEN34788 /UMRANIYE/ISTANBUL
Tel:[phone] Pbx.
Fax:[phone]
e-mail :[e-mail]
[e-mail]
web:www.yilmazmachine.com.tr
Forminimizethedocumantation,Itiswerynecessarytomentionbelowdetailsattheagreementssignedwith
suppliersanddealersofthepurchasedmachines
*Machinemodel*Dateofpurchase
*Machine’sserialnumber*Averagedailyoperationperiod
*Voltageandfrequency*Descriptionofthemachinefault
*Nameofdealerwheremachinewaspurchased
2.MACHINE’SDESCRIPTIONAND TECHNICALFEATURES
2.1.MACHINE’SDESCRIPTION
Cutting machinewithcirclesawforcutting PVC,Aluminiumandwoodenprofilesindesiredangles.
ØIthastheabilitytocutinshape.
ØMachineworkingdirectionisadjustable.
ØThecuttinng in450600900degreesanglesisbyswitchbladeandtheotheranglesfree cuttingispossible.

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ACCESSORIES
STANDARD ACCESSORIES OPTIONALACCESSORIES
SliceequipmentSpraymistcooling system
Ø420 mm.circlesaw PneumaticClamps
SupportequipmentAdditionSawBlade
2.2TECHNICALFEATURES
TEKN KÖZELL KLER
TECHNICALFEATURES
MK420 2.2kW50 Hz
400VAC3PE d=30/32mm D=420 mm. 3000dev/dak
RPM 63x98x140 132 164
Kg
W
H
L
d
D
cm
TEKN KÖZELL KLER
TECHNICALFEATURES
MK420 2.2kW50 Hz
400VAC3PE d=30/32mm D=420 mm. 3000dev/dak
RPM 63x98x140 132 164
Kg
W
H
L
d
D
cm

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2.3CUTTINGDIAGRAM

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2.4OVERALL DIMENSIONS
PICTURE1
2.5PARTLISTS

Ylmaz PVCveAlm. İşleme MakineleriLtd.Ştd
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PICTURE2
PART
NO PARTNAME QTY
1 221-016 PlasticHandle 1
2 550-138 SwitchBladeMK420) 1
3 550-140 P2-562008Pipe 2
5 Clamp 2
7 550-031 Dolly(KD300) 1
8 211-055 01 FrameBottomTable 1
10 141-442 FootAdjustmentScrew 4
16 150-080 PedalPlate 1
20 211-055 Frame 1
28 222-010 CoverHandle 5
37 162-068 MotorStarter 1
45 222-074 HandleHousing 1
49 150-074 MeterReading Washer 1
50 141-501 HandleFastening Washer 2
51 141-139 Squeezing Handle 5
52 235-013 Ruler(Saw) 1
54 150-093 Table 1
72 201-005 420 MMSaw 1
93 172-025 M8x16 Imbus 6
105 111-291 SetSquare 1
108 235-015 S.SquareDegree Label 1
111 113-009 ClampHousing
(Mechanic) 2
119 150-102 FrameConnectionPlate 2
120 222-061 FrontProtector 1

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PICTURE3
PART
NO PARTNAME QTY
51 141-139 Squeezing Handle 5
114 111-294 Cutting DollyShaftHousing1
115 141-579 Cutting DollyProfileShaft 1
116 116-010 Cutting DollyProfile 1
118 235-014 MeasurementRuler(Cutting
Dolly) 1

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PICTURE4
PARTNOPARTNAME QTY
29 141-509 TableRaising PlateDolly 1
69 141-499 SawShaft 1
72 201-005 420 mm Saw 1
73 150-085 ExternalCoupling 1
74 141-035 JointWasher30x10x9 1
75 171-002 M10x25 1
94 150-078 TableRaising Plate 1

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3.SAFETY
3.1.SAFETYINFORMATION
Thesymbolsshownhereunderarenecessarytobereadwithspecialattention.Notreading orobserving
ofthemmaycausedamagetotheequipmentorpersonalinjury.
The IMPORTANT symbolaboveisonetelling toapplyspecialcareandtobecarefulatcarrying outthespecified
operation.
The CAUTION! Symbolabovewarnsyouagainstspecificdangers, andrequirestoreadthetext.Notobserving may
causedamagetotheequipment.
DANGERWARNING
TheDANGERWARNINGabovewarnsyouagainstspecificdangers, anddefinitelyrequiresthetexttoread.
Notobservingmay resultinseriousbodilyinjury.
Pleasereadthe user’smanualcarefullybefore usingthemachineorcarryingoutmaintenance.
IMPORTANT
CAUTION

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3.2ACCIDENTPREVENTION
3.2.1Ourmachinesaremanufacturedinaccordance withEN60204-1andEN292-2CEsafetydirectives, which
covernationalandinternationalsafetydirectives.
3.2.2Itisthetaskoftheemployertowarnhisstaff againstaccidentrisks, totrainthemonpreventionofaccidents, to
providefornecessarysafetyequipmentanddevicesfortheoperator’ssafety.
3.2.3Beforestarting toworkwiththemachine, theoperatorshouldcheckthefeaturesofthemachine, learnall
etailsofthemachine'soperation.
3.2.4Themachineshouldbeoperatedonlybystaffmembers, whohavereadandunderstood thecontentsofthis
manual.
3.2.5All directives, recommendationsandgeneralsafetyrulescontainedinthismanualhavetobeobservedfully.
Themachinecannotbeoperatedinanywayforpurposesotherthanthosedescribedherein.Otherwise, the
manufacturershall notbedeemedresponsibleforanydamagesorinjuries. Andsuchcircumstanceswouldlead
totheterminationofthewarranty.

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3.3.GENERALSAFETYINFORMATION
3.3.1.Thepowercableshouldbeledinsuchawaythatnobodycansteponitornothing canbeplacedonit.
Specialcare hastobetakenregarding theinletandoutletsockets.
3.3.2.If thepowercableshouldbedamagedduring operation,don'ttouchandunplug it.Neverusedamaged
powercables.
3.3.3.Don’toverloadmachinesfordrilling and cutting.Yourmachinewill operatemoresafelywithpower
supplyinaccordance withthestipulatedvalues.
3.3.4.Don’tplace yourhandsbetweenpartsinmotion.
3.3.5.Usecorrectilluminationforthesafetyoftheoperator.(ISO8995-89 StandardTheLighting ofIndoor
WorkSystems)
3.3.6.Useprotectiveeyeglassesandearplugs. Don'twearoversizeclothesandjewels. Thesecanbecaught
bymovingparts.
3.3.7.Don’tuseanymaterialsotherthanthoserecommendedbythemanufacturerforcutting operationson
themachine.
3.3.8.Ensurethattheworkpiece isclampedappropriatelybythemachine'sclamporvice.
3.3.9.Ensuresafeworkingposition,alwayskeepyourbalance.
3.3.10.Don'tleaveanythingonthemachine.
3.3.11.Keepyourworking placealwaysclean,dryandtidyforaccidentpreventionandsafeoperation.

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3.3.12.Keepyourmachinealwayscleanforsafeoperation.Followtheinstructionsatmaintenance andreplacement
ofaccessories. Checktheplug andcableregularly.If damaged,letitreplacebyaqualifiedelectrician.
Keephandlesandgripsfree ofanyoil andgrease.
3.3.13.Unplug first,beforeconducting andmaintenanceworks.
3.3.14.Ensurethatanykeysoradjustmenttoolshavebeenremovedbeforeoperating themachine.
3.3.15.If youarerequiredtooperatethemachineoutside, useonlyappropriateextensioncables.
3.3.16.Repairs shouldbecarriedoutbyqualifiedtechniciansonly.Otherwise, accidentsmayoccur.
3.3.17.Beforestarting anewoperation,checktheappropriatefunctionofprotectivedevicesandtools, ensurethat
theyworkproperly.Allconditionshavetobefulfilledinordertoensureproperoperationofyourmachine.
Damagedprotectivepartsandequipmenthavetobereplacedorrepairedproperly(bythemanufactureror
dealer).
3.3.18.Don’tusemachineswithimproperfunctioning buttonsandswitches.
3.3.19.Don’tkeepflammable,combustiveliquidsandmaterialsnexttothemachineandelectricconnections.

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4.TRANSPORTOFTHEMACHINE
*Thetransportshouldbedonebyqualifiedpersonnelonly.
4.1.Themachineshouldbetransportedbylifting withproperequipment(nottouching thegroundduring the
transport). (Themachinecanbehandledthrough thesidehandles(Figure2. NO.28))
4.2.Machinesarecoveredwithnylonfordelivery,unless thecustomerhasnotrequiredothermethod ofpacking.
4.3.Fortheweightandoverall dimensionsofthemachineseeTechnicalFeatures.
5.INSTALLATIONOFTHEMACHINEAND CONNECTIONTOTHEPOWERSOURCE
Removetheboltsandstoppersforfixing themovablepartsofthemachineforsafetransportbeforemakingthe
powerconnections.
5.1.Place yourmachineontoanevenground.Themachine’soverall dimensionsare givenunder OVERALL
DIMENSIONS.Theworking place shouldbeappropriateforthesedimensions.
5.2Withtheaidofadjustablefoot(Figure2NO.10)adjustthebalance ofthemachine
5.3Yourmachineoperatesunder400V50 Hzpowersupply.Lettheelectricinstallationcarryoutbyaqualified
electrician.
5.4Checktherotationdirectionofthesawafter makingtheelectricconnection.
IMPORTANT
IMPORTANT

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6.MACHINESAFETYINFORMATION
Readtheuser’smanualcarefullybefore startingtooperatethemachine. Followtheinstructionsinthemanual.
6.1 Themachinehastooperatedwith400V50 Hz. Lettheelectricinstallationcarryoutbyaqualifiedelectrician.
6.2 Lifting,installation,electricmaintenance ofthemachineshouldbecarriedoutbyqualifiedpersonnelonly.
6.3 Routinemaintenance andscheduledmaintenance shouldbecarriedoutbyqualifiedpersonnelafterunplugging
themachinefirst.
6.4 Ensurethatthemachinehasbeencleaned,testedandmaintainedbeforestarting tooperateit.
6.5 Checkthesafetydevices, powercableandmovingpartsregularly.Don’toperatethemachinebeforehaving
replaceddefectivesafetydevicesorfaultyparts.
6.6 Keepforeign materialsawayfromtheworking areaofthemachine, keepawayfromthemachine’smovingparts.
6.7 Don’tusethemachineforimproperpurposes(forworking ofironandferrousmetals)

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7.OPERATION
7.1.CUTTINGPROCESS
Before startingtocuttingverifythedirectionofrotationofsaw.Label,indicatingdirectionofrotationisplaced
ontherighthandsideofthemachine
After placingthemachineremovetheframeconnectionplates(Figure 2NO.119)usedfortransportation
7.1.1Openthe mainschalterofthemachine.
7.1.2Place theprofileonthetableandfastenwiththeaidofclamps(Figure2NO.5). (Thesawmightcuttheclamp
fromtheends;becarefulwhileusingclamps.)
7.1.3Press startbuttonthatisplacedonthemotorstarter(Figure2NO.37).Thesawwill startrotating.
7.1.4Raisethehandle(Figure2NO.1).Sawwill startcutting.Holdthehandle raiseduntil cutting process is
completed. (Adjustthemovementspeedofthesawaccordingtotheprofileyou’ll cut(Aluminum,PVC,
Wood))
7.1.5Aftercompleting thecutting process lowerthehandleslowly.
*CUTTINGIN ANGLE : Cutting withananglecanbeperformedwiththismachine. Forthisprocessloosen
thepipes(Figure2NO.3)placedonthesetsquare(Figure2NO.105).Opentheswitchblade(Figure2NO.2).
Thenadjustthesetsquarethrough theangleruler(Figure2NO.108)totherequiredangle. Angleadjusting
pointis placedonthetable. Thensqueeze thepipes. Place theswitchbladeinitsplace andperformnormal
cutting.
(Cutting anglesthatcanbeperformedbyusing switchbladeisgiveninTECHNICALSPECIFICATIONS
section.Donotuseswitchbladeinintermediateangles)
* Infixedlengthprofilecutting modesyoucanusedolly(Figure2NO.7).
* Onecanadjusttheworking sideofthemachineasrequested. Press thepedal(Figure2NO.16)locatedonthe
bottomframe(Figure2NO.8).Theframewill moveupwards. Whileyouarepressing thepedalrotatethetop
bodythrough therequesteddirection andreleasethepedal.
*Thedistance thatthesawraisesorlowerscanbeadjustedwiththeaidofwashers(Figure2NO.50)onthefront
sideoftheframeandwiththeaidofmeasurementruler(Figure2NO.52).

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7.2. CUTTINGIN SHAPEPROCESS
7.2.1Forcutting inshapeprocess themachineshouldbeinapositionasindicatedinFigure3.Fisrtofall loosenthe
pipesplacedonthesetsquareandtakeoutthesetsquaregroup.
7.2.2Removethefrontprotector(Figure2NO.120).
7.2.3Install cutting inshapeapparatustoitsplace ascanbeseeninFigure3andfastenwithaM8Imbusbolt.
7.2.4Adjustthewidthdimensionoftheprofiletobecutinshapethrough thedimensionruler(RESIM3NO.118)on
theshaft(Figure3NO.115)andfixtheshaftbysqueezing thesqueezing handle(Figure3NO.51).
7.2.5Adjustthesawraising heightthrough therulerplacedonthefrontofthemachine(Figure2NO.52).
Afterthatbyfastening bothofthewashers, (Figure2NO.50)fastenthesaw.
7.2.6Operatethemachineandgettothebacksideofthemachine.
7.2.7Place theprofileontothetableandleanoneendofittoleaning profile(Figure2NO.116).Feedtheprofile
forwarduntil cutting inshapeprocess iscompleted.
7.2.8 Stopthemachineafter finishingworking
7.3.CHANGINGTHESAW
7.3.1Disconnectfromelectricpowersupply.
7.3.2Holdthesawfromthebottom.Loosenthesawfastening washers(Figure2NO.50)byhalfopening the
squeezing handles(Figure2NO.51).
7.3.3RemovethetwoM8Imbusbolts(Figure2NO.93)with6Allenkeyplacedonthetable(Figure2NO.54)
7.3.4RaisethetableascanbeseeninFigure4fromthehandle(Figure2NO.28).Meanwhileplace thetableraising
plate’s(Figure4NO.94)groove, tothatofdolly’s(Figure4NO.29)andputthetableinplace. Thetablewill
standopenitself(Figure4). (Besure thatthetableisfixedappropriately;otherwisetablemay fall andcause
personelinjury)
7.3.5Take17 keyononehandanda15 keyontheother.Withkey17 holdM10 bolt(Figure4NO.75),andwiththe
otherkey,sawshaft(Figure4NO.69)through thekeyplace.
7.3.6RemoveM10 boltandthenjointwasherandexternalcoupling inorder(Figure4NO.73 and74).Thenremove
thesawandchangewithanewone. Inreverseorderinstall theitemsyouremoved.
IMPORTANT:Install thesawappropriatetodirectionofrotation. Label,indicatingdirectionofrotation
isplacedontherighthandsideofthemachine. Donotforgetthetools, usedforchangingthesaw,inside
oronthemachineafter completingthechangeprocess.

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7.3.7Aftercompleting sawchangeraisethetablealittlebit.Pushbyhandtableraising item(Figure4NO.94)
backwardsandreleasefromthegroove, thenlowerthetableslowly.
7.3.8Fixthetablebyinstalling thepre-removedtwopiecesofM8Imbusbolts(Figure2NO.93)
7.4ANGULAR ADJUSMENTAND CORRECTNESSCONTROLOFSAWBLADEAND SET SQUARE
If youencounterproblemsduring cutting operation(ie. Angularcutting)
7.4.1 Performeyecontroltotherun outoftheblade. If possiblewiththehelpofadialgauge.
7.4.2 If thereexistsproblemduring angularcutting,checktheperpendiculartiyofthesawbladewiththehelpofan
edgeknifesetsquare. If theperpendicularityisnotcorrect,, loosenthehandlenutsthatfixthesetsquare(fig2
no3)andnutsthatfixthesafetycatchonthesetsquare. (fig2no2)Turnthesetsuaresmoothlysothatthe
perpendicularitycanbeachievedaccordingtothesawblade. Afteradjusting theperpendiculeritytightenthe
handle.andplace thesafetycatchtoitspositionandtightenthenutsagain.
7.5ADJUSTOFBELT TENSION
Adjusting ofthebelttension,squeeze thescrewshownin
PICTURE5till givendimension(20 mm).Checkthetension
ofthebeltbypressing onthebeltwithyourfinger.Stretching
distance ofthebeltshouldbeapproximately10 mm.
PICTURE5