GK4235 Operation Manual

OPERATION MANUAL
Double Column Band Sawing Machine
Model GH4228
Model GH4235
Contents
1. Main Specification ......................................................................................................................1
2. Main Components of Sawing Machine.........................................................................................1
3. Selection of Teeth Number of Saw Blade for Variable Stocks......................................................2
4. Attention for Usage of New Saw Blade Selected..........................................................................3
5. Installation Methods for the Saw Blade ........................................................................................4
6. Fixture Stock .................................................................................................................................5
7. Hydraulic System..........................................................................................................................6
8. Electrical Principle Chart ..............................................................................................................8
9. Operation and Maintenance ..........................................................................................................9
10. Usual Major Faults and Solution...............................................................................................10
11. Precautions ................................................................................................................................14
12. Packing List ..............................................................................................................................14
1. Main Specification
Parameter
GH4228
GH4235
Φ280□280x280
Φ350□350x350
Three grade:27/45/69
Three grade:27/45/69
Hydraulic stepless
Hydraulic stepless
3505x27x0.9
4115x34x1.1
Hydraulic
Hydraulic
Main motor power (kw)
2.2
3
Hydraulic
pump
power(kw)
Coolant pump power(kw)
0.55
0.55
0.04
0.04
Type of main transmission
Worm bar
Worm bar
1800x1100x1350
2000x1100x1450
Max. cutting range (mm)
Cutting speed (m/min)
Feeding speed adjustment
Blade model (mm)
Clamping type
Machine layout (mm)
2. Main Components of Sawing Machine
Saw frame
Sub-column
Base
Leading
Clamping
Saw
Electrical
Coolant
Operation
device
wheel
cabinet
tank
station
Oil pump
Motor
Reducer
Coolant
Main oil
pump
cylinder
device
Clamping
Working
Driving
Tension
cylinder
light
wheel
base
1
3. Selection of Teeth Number of Saw Blade
for Variable Stocks
Cutting length
Less 15
15-25
25-75
75-150
150-250
12-10
10-8
8-6
6-4
4-3
8-6
4-3
3-2
(mm)
Teeth number
(difficult)
Teeth number
(general)
2
4. Attention for Usage of New Saw Blade
Selected
1.
Before loading the new saw blade, keeping the cleaning of the saw
blade wheel and checking if coolant and hydraulic system work
normally
2.
Fine and coarse teeth saw blade should be applied according to size
of stocks, please check the above item 3 to choose the suitable saw
blade for your stock so that no any teeth of saw blade broken. For
example, if using small teeth blade (6 teeth blade) to cut big
work-piece (150mm diameter steel rod) will cause too much iron
scurf between teeth, further decrease blade service life.
3.
Cutting speed should be lower while cutting material with quite
high hardness
4.
The saw blade selecting also should be considered as per the shape
of the stock, teeth-change blade should be used for the profile stock,
keep at least two tooth inside the stock constantly
5.
Reasonable to choose coolant liquid for variable stock, oil and
water ratio can be 1:5 for high alloy steel and 1:10 for low alloy
steel and carbon steel
3
5. Installation Methods for the Saw Blade
1. Checking the saw blade and welding coupling before installation
2. Up rise the saw frame to 1-1.1m height, and open the front cover,
follow the marks instruction (loosen and clamp) to rotate up the lead
screw 5-7cm, loosen right and left landing legs’ screws, make sure
3-5mm distance between two clamping blocks
3. Install blade onto two wheels and guiding box, keep blade back close
to blade back bearing, rotate valve to tension blade. The clamping
force of blade was normally about 25-35N.M. Too high feed rate and
cutting speed with strong impact force between blade and work-piece
may cause blade broken
4. Power on and off and make the blade rotating gradually for 3 rounds,
till the saw blade into normal working
5. Keeping the machine into free working for 2-3 minutes for checking
without any abnormal happened
4
Figure 1
5
Rail steel
C steel
H steel
U steel
Angle
steel
Square
tube
Round bar
Pipe
profile
Hexagonal
bar
Shape
1 Piece
2 Piece
3 Piece
4 Piece
5 Piece
Fixture methods for stocks with variable shapes
6 Piece
Multiple
pieces
6. Fixture Stock
See the Figure 1 for the clamping of variable stocks
7. Hydraulic System
The hydraulic system was used for:
(1)
Up and down of saw frame
(2)
Clamping and unclamping of stock
(3)
Blade feeding speed, system pressure:1.8-2.0Mpa
No.
Model
Name
QTY
1
WU25-100
Filter
1
2
CB-B6
Gear pump
1
6 liter
3
YS712-4
Motor
1
0.55kw/1440rpm
4
P-B10B
Overflow valve
1
5
DSG-032-3C2-24V
Electrical-magnetic valve
(3 positions;4-way)
1
6
HDJ-10Y
Throttle Valves
1
7
22C-10
Stroke valve (2 positions,2 way)
1
8
340-10
Selector valve (3 positions,4 ways)
1
6
Remark
Hydraulic Schematic
7
8. Electrical Principle Chart
8
9. Operation and Maintenance
1. Checking the power source with correct wire connecting and keep the
suitable coolant liquid and hydraulic oil
2. Idle running machine and assure the machine with right rotating
direction and fluent coolant and moving of up and down
3. Adjusting the stock stopper with right position of cutting length, and
stock is in clamping status
4. Keeping the stock bracket at suitable height
5. Adjusting the up-valve and down-valve and make the saw blade 2cm
higher than the stock, and adjust the stroke quill and make sure that
the stroke switch can be touched properly during up rising and cutting
off of saw blade
6. Lubrication oil should be changed periodically
7. Lubrication oil No.32 was applicable for the sliding parts, such as
clamping vise, main column, sub-column
8. Any parts of the personal body should be away from the running blade
9. Overload operation will cause a hard damage to the machine
10. Blade changing should be operated after power off
11. Keep clean environment around the machine
12. Power off the main switch while stopping the machine and rise-up the
bracing, opening the vise and saw blade
9
10. Usual Major Faults And Solution
10.1 Mechanical parts
Faults
Teeth broken
Teeth tip wear off
Harsh Section of saw
blade
Sharp sound while
cutting
Main reason caused
Solution
High feeding rate
Decrease the feeding rate
Oversize teeth selected
Change blade with smaller teeth
Wrong fixture of irregular stock
Revise the fixture
No match up of blade
Test blade firstly
High speed rotating of saw blade
Lower speed
Higher hardness of material
Change the saw blade into high hardness
Cutting coolant liquid density
Increase the density
Wrong coolant liquid chosen
Change the coolant liquid number
Higher feeding rate
Lower the feeding speed
Higher feeding rate
Lower the feeding speed
Wrong coolant chosen
Choose the suitable coolant
Unqualified saw blade
Change the blade
Over speed of saw blade
Decrease the speed
Irregular surface of welding joint
Grind the welding joint
Wrong coolant chosen
Change the coolant
Tolerance between leading box and saw blade
Adjust the tolerance again
Over feeding rate and higher pressure
Lower the feeding speed
10
Faults
Geometrical
accuracy
out
tolerance
Main reason caused
Solution
Low tension of saw blade
Decrease the saw speed
Split teeth or lower symmetry
Change new saw blade
Far distance between leading bracket and stock
Adjust the distance less than 3cm
Teeth wear out
Change saw blade
Un-perpendicular between saw blade and vise
Adjust leading box
Low tension of saw blade
Tension the saw blade
Unbalance driven wheel and driving wheel
Adjust the tension nuts
Bearing broken inside
Change bearing
Abrasion inner hole with the shaft
Change the driving wheel
Wheel abrasion and reducer damage
Change the wheel
Abrasion of warm bar and warm gear
Change the bar or gear
Out of oil in the reducer box
Oil charging
Low pressure
Adjust the relief valve
Oil route blocking or leaking
Clean or change the valve, filter, bracing
the joint
Stroke switch out of service
Repair or change the switch
Wiring failure
Check the wire diagram
Speed-adjust valve blocking
Clean or change the valve
Descending valve out of work
Check the oil route
High back-pressure
Adjust the pressure
Valve’s core locking inside
Clean the core of valve
of
Saw blade drop off
Noise of reducer box
No manual up rising
or auto-rising of saw
frame and
No descending or
even descending of
saw frame
11
Faults
Main reason caused
Un-vacuum oil cylinder
Solution
Discharge the air
10.2 Electrical parts
Faults
No power supply and
oil pump does not work
once turning on the
main switch
Machine still work
when pushing the stop
button
machine does not work
when pushing the start
button
Machine still work after
cutting off stock
Indicator out of work
Main reason caused
Solution
Power source no connecting
Connect the power
Short cut electricity
Repair or change the breaker
Open the emergency stop button
Reset the stop button
Button broken
Change the button
Wiring failure
Check the wire diagram
Button for saw blade broken
Repair or change the button
Wiring failure
Check the wire diagram
Stroke switch out of work
Repair or Change he switch
Limit switch out of work
Repair or change the switch
Limit nut not in right position
Adjust the nut into right position
Transformer broken
Repair or change the transformer
Indicator broken
change the indicator
12
10.3 Hydraulic parts
Faults
No Oil pumping
Main reason caused
Solution
Filter blocking
Clean or change the filter
Low oil level, should be 2-3cm higher
Add hydraulic oil
High oil viscosity
Change the oil
Low air exhausting
Reciprocate moving up and
down of saw frame and exhaust
the air extremely
Oil leaking
Brace the coupling
Seals leaking of oil pump shaft
Chang the sealing ring
Oil return pipe above oil surface
Submerge the oil tube
Oil pump wear out or broken
Chang the pump
Wrong rotating direction of
oil pump
Incorrect wiring connecting
Check the wire diagram
High oil temperature
Oil pump wear out or broken
Repair or change pump
Low oil viscosity
Change oil
High oil pressure
Adjust the pressure
Over tolerance between the core of selector valve
and valve hole
Repair or change selector valve
Sealing ring broken of oil cylinder
Repair or change the sealing
ring
Speed-adjusting valve open
Close the valve
Oil foaming
Saw frame auto descending at
middle level
13
11. Precautions
1. Please read the manual books carefully and get to know this machine
before operating
2. Balancing the machine after installation
3. Clean oil cylinder before adding oil, clean 32# oil is best choice, but
46# oil is required if environment temperature above 30℃
4. Ground wiring should be wiring at least 50cm below the ground
5. Power voltages should be controlled at the range of ±10% of machine
voltage, in case of damaging the electrical components
12. Packing List
No.
Name
Qty
1
Bi-metal saw blade
1 piece
2
Roller rack
1 set
3
Tool box
1 set
4
Manual book
1 copy
5
Inspection report
1 piece
14
Remark

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