Cosen C3 Instruction Manual

Nc fully automatic horizontal bandsaw

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COSEN SAWS

NC Fully Automatic

Horizontal Bandsaw

Instruction Manual

The Pinnacle of Cutting Performance

(Non‐CE & CE Models)

Cosen Mechatronics Co., Ltd.

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Summary of Contents for Cosen C3

Page 1 COSEN SAWS NC Fully Automatic Horizontal Bandsaw (Non‐CE & CE Models) Instruction Manual The Pinnacle of Cutting Performance Cosen Mechatronics Co., Ltd. ...
Page 2 1-704-943-1031 Instruction Manual: C3 NC Fully Automatic Horizontal Bandsaw Ver. 8 2017/06/13 © 2013 by COSEN MECHATRONICS CO., LTD. No part of this publication may be photocopied or otherwise reproduced without the prior written permission of COSEN. Printed in Taiwan...
Page 3 Safety rules  Make sure your work area is cleared of uninvited people and obstacles every time before you start operating the machine.  Never wear gloves or loose clothing when operating the machine. It may lead to serious injury if they are caught in the running machine. Wrap or cover long hair.  Use a water‐soluble cutting fluid on this machine. Oil‐based cutting fluids may emit smoke or catch fire, depending on how they are used. ii ...
Page 4 Safety rules  Never cut carbon or any other material that may produce and disperse explosive dust. It is possible that sparks from motors and other machine parts will ignite and explode the air‐borne dust.  Make sure any use of fire is prohibited in the shop and install a fire extinguisher or other fire control device near the machine when cutting titanium, magnesium, or any other material that produces flammable chips. Never leave the machine unattended when cutting flammable materials.  Never adjust the wire brush or remove chips while the saw blade is still running. It is extremely dangerous if hands or clothing are caught by the running blade.  Never touch the running saw blade with gloves or not. It is dangerous if your hands, clothing or gloves are caught by the running blade. iii ...
Page 5 Safety rules  Stop the saw blade before you clean the machine. It is dangerous if hands or clothing are caught by the running blade.  Never start the saw blade unless the workpiece has been clamped firmly. If the workpiece is not securely clamped, it will be forced out of the vise during cutting.  Take preventive measures when cutting thin or short pieces from the work to keep them from falling. It is dangerous if the cut pieces fall. iv ...
Page 6 Safety rules  Use roller tables at the front and rear sides of the machine when cutting long work. It is dangerous if the work piece falls off the machine.  Never step or stand on the roller table. Your foot may slip or trip on the rollers and you will fall.  Turn off the shop circuit breaker switch before performing maintenance on the machine. Post a sign indicating the machine is under maintenance. v ...
Page 7: Table Of Contents
Table of Contents Safety Information 1‐1 Section 1 – Safety Instructions …………………………………………………………………………………………………….. 1‐1 Safeguard Devices ……………………………………………………………………………………………………… 1‐3 Emergency Stop ………………………………………………………………………………………………………… 1‐4 Illustration: Emergency Stop ……………………………………………………………………………………… 1‐5 Safety Labels …………………………………………………………………………………………………………….. 1‐6 1‐9 Illustration: Safety Labels ………………………………………………………………………………………..… Hearing Protection …………………………………………………………………………………………………….. 1‐10 CE Compliance ………………………………………………………………………………………………………….. 1‐10 Risk Assessment ……………………………………………………………………………………………………….. 1‐10 General Information 2‐1 Section 2 – Specification ……………………………………..…………………………………………………………………….. 2‐2 Machine Parts Identification ……………………………………………………………………………………… 2‐3 Floor Plan …………………………………………………………………………………………………..……………… 2‐4 Moving & Installation ...
Page 8 Table of Contents Blade Descend Pressure & Speed ………..…………………………………………………….…. 4‐7 HMI Touch Screen & Functions …………………………………………………………….………. 4‐7 HMI Error Codes ………………………..……………………………………………………….………… 4‐20 Standard Accessories ………….………………………..……………………………………………….………….. 4‐21 Optional Accessories …….…….………………………..…………………………………………….…………….. 4‐24 Unrolling & Installing the Blade …………………………………………………………………….…………… 4‐26 Adjusting Wire Brush ………..……………………………………………………………………….……………… 4‐28 Adjusting Saw Arm……………..……………………………………………………………………….……………… 4‐28 Adjusting Blade Speed ………..………..…………………………………………………………………………… 4‐29 Breaking‐In the Blade ………..………..…………………………………………………………………..………… 4‐29 Placing Workpiece onto Workbed ………………………..……..………..…………………………………… 4‐29 Positioning Workpiece for Cutting ………..………..………………………………….……………………… 4‐30 Without Using Automatic First Cut Function…………………………………………………. 4‐30 ...
Page 9 Table of Contents Every Three Months ………………..…………………………………………….……………………… 8‐2 Every Six Months ……………….………………………………………………….……………………… 8‐3 Storage Conditions …………………………..………..………………………………………………………….. 8‐3 Terminating the Use of Machine ……..…………..………………………………………………………….. 8‐3 Oil Recommendation for Maintenance …………………………………………………………………….. 8‐4 Troubleshooting 9‐1 Section 9 – Introduction ……………………….…….…………………..………………………………………………………….. 9‐1 Precautions ………………….…………………..……………………………………………………………………..9‐2 General Troubles & Solutions ………………………..………………………………………………………….. 9‐2 Minor Troubles & Solutions ………………………..………………………………………………..………….. 9‐3 Motor Troubles & Solutions ………………………..…………………………………………………..……….. 9‐3 Blade Troubles & Solutions ………………………..…………………………………………………………….. 9‐4 Sawing Problems & Solutions ………………………..………………………………………………………….. 9‐5 Re‐Adjusting the Roller Table ………………………..………………………………………………………….. 9‐6 Parts 10‐1 Section 10 – ...
Page 10: Section 1 - Safety Information
Section 1 SAFETY INFORMATION SAFETY INSTRUCTIONS SAFEGUARD DEVICES EMERGENCY STOP SAFETY LABELS HEARING PROTECTION CE COMPLIANCE RISK ASSESSMENT Safety is a combination of a well‐designed machine, operator’s knowledge about the machine and alertness at all times. COSEN’s band machine has incorporated many safety measures during the design process and used protective devices to prevent personal injuries and potential risks. Warning labels also serve as a reminder to the operator. Throughout this manual, you will also see various safety‐related symbols indicating important information that you should take note of prior to use of the machine or part of its functions. These important safety instructions do not cover all possible situations that might occur. It is your responsibility to take caution and follow procedures stated in this manual when installing, maintaining and operating your machine. Cosen will not be liable for damages resulting from improper use. SAFETY INSTRUCTIONS What the icons and signs in this user manual mean: This icon marks DANGER; hazards or unsafe practices that may result in severe personal injury or death. This icon marks WARNING; hazards or unsafe practices that may result in personal injury or damage to the machine. This icon marks CAUTION; information that should be read before use to prevent damage to the machine. Supplementary information to the procedures described in this manual. Call your local agent or our service center for help. ...
Page 11 This manual has important safety All users must read it before performing any information. Read through it carefully activity on the machine, such as replacing before operating this machine to prevent the saw band or doing regular maintenance. personal injury or machine damage. Learn the operation, limitation and the specific Some personal protective equipment is potential hazards peculiar to this band required for the safe use of the machine, e.g. protection goggles. saw. Do not operate this machine unless it is Keep blade protection cover and wheel completely assembled. covers in place and in working order. Make sure the power switch is off before Use recommended accessories. Improper plugging in power cord. accessories may be hazardous. Disconnect the power cord before making Keep your work area well illuminated at adjustment, maintenance or blade minimum 500 lumen. changes. Keep your work area clean. Cluttered and Keep all guards and shields in place before slippery floors invite accidents. installing or starting up the machine. Remove adjusting keys, wrenches or any Wear proper apparel during operation loose parts or items from the machine and when servicing the machine. ...
Page 12: Safeguard Devices
SAFEGUARD DEVICES The safeguard devices incorporated in this machine include the following two main parts: 1. Protection covers & guards 2. Safety‐related switches Protection Covers & Guards 1. Idle wheel housing cover 2. Drive wheel housing cover 3. Gear reducer cover 4. Wire brush belt cover 5. Blade guard cover (left & right) 6. Chip conveyor cover (CE model only) The protection devices should always be mounted on the machine whenever the machine is running. Do not remove any of these safeguard devices under any circumstances except when servicing the machine. Even skilled service technicians should still take cautions when performing repairs or service on the machine with any of these protectors removed. It is the responsibility of the user to make sure all these elements are not lost and damaged. Take note of the following main moving parts on the machine prior to and during machine operation:  Saw bow assembly  Drive and idle wheels  Blade guide arm  Saw blade guide rollers  Quick approach device  Wire brush ...
Page 13: Emergency Stop
Safety Related Switches To protect the operator, the following safety related switches on the machine are actuated when the machine is in operation. Wheel motion detector This is a proximity sensor used to detect the motion of the drive wheel. Once the saw blade is broken or as soon as it starts slipping, the sensor will detect and stop the drive wheel and the machine. Power switch Located on the cover of electrical cabinet, the power switch controls the main power of the machine. Up to your company’s internal rules, this power switch can be locked with a padlock or a luggage lock to protect the operator and the machine. Emergency stop button Located on the control panel, the button when pressed will stop the machine completely. Vise clamp switch This switch assures firm clamping of the workpiece. If the workpiece is not clamped properly, the saw blade is not allowed to run. Wheel cover interlock switches Located on the two wheel housings, these switches (CE model only) are used to assure that the machine will stop whenever the wheel covers are open. This device is to protect users from being cut by the running saw blades. Among all these safety switches, some of them are used to protect the users and some of them are used to prevent damage to saw blades, the workpiece and the machine itself, etc. We have taken every precaution to prevent injury or damage and to provide safe and economical operation of the machine. EMERGENCY STOP Designed to be easily accessible, the emergency stop button is located on the left bottom corner on the control panel and is made in red color and rubber material. For CE models, supplementary emergency stop button may be available at other area(s) of the machine depending on machine type. ...
Page 14: Illustration: Emergency Stop
Illustration: Emergency Stop Emergency Stop 急停按鈕 1‐5...
Page 15: Safety Labels
SAFETY LABELS Safety‐related labels mounted on the machine are categorized into the following four categories. Please read through and understand them before operating the machine. Refer to Illustration: Safety Labels. DANGER Labels A red and white DANGER labels marks s hazards or unsafe practices that will result in severe personal injury or death. Label Meaning Label Meaning Hazardous Voltage DANGER: Running Blade Blade runs through this area. Keep TURN POWER OFF before your hands away from a running servicing. Failure to blade to avoid severe injury. The following the warning can arrow indicates direction of the result in severe injury. blade. WARNING Labels An orange and black WARNING label marks hazards or unsafe practices that can result in severe personal injury or damage to the machine. Label Meaning Label Meaning Cutting Hazard Cutting Hazard KEEP COVER CLOSED while KEEP HAND OFF while the blade is ...
Page 16 CAUTION Labels Yellow and black CAUTION labels mark hazards or unsafe practices that can result in considerable personal injury. Label Meaning Keep hands out of the machine while the blade is running. Power to machine must be turned off when changing blades or adjusting wire brush. NOTICE Labels Blue and white NOTICE labels mean unsafe practices that could result in damage to products or property. Label Meaning Replace the hydraulic oil every six months or every 1,200 hours of operation. Oil specification: Shell TELLUS 27 or Mobil DTE OIL LIGHT / HYDRAULIC 28 To extend blade life, always adjust the location of wire brush so that it is properly touching the blade. Also replace a worn wire brush with a new one. 1‐7...
Page 17 SAFETY INSTRUCTION Labels Green and white SAFETY INSTRUCTIONS are important reminders that should be read before operating the machine. Label Meaning 1. Read and understand the instruction manual and warning signs before operating machine. Failure to follow these instructions and warnings can result in serious injury or death. 2. Do not wear gloves, neckties, jewelry or loose clothing while operating the machine. 3. Always wear eye protection goggles. 4. Check blade tension and adjust blade guide before starting to cut. 5. Always clamp stock firmly in place before cutting. 6. Do not remove jammed or cut‐off pieces until blade has stopped. 7. Keep fingers out of path of blade. 8. Blade guards should be in place and used at all times. 9. Disconnect machine from power source before marking repairs or adjustments. 10. Do not operate while under the influence of drugs, alcohol or medication. 1‐8 ...
Page 18: Illustration: Safety Labels
Illustration: Safety Labels 1‐9...
Page 19: Hearing Protection
Drive wheel  Parts not assembled tightly causing mechanical vibration When your machine is running, noise will come out. This is a machine‐electric interface problem that may make people feel uncomfortable. Our products pass noise testing less than 78 dBA. If your machine produces an undesirable noise while it is running, you should: Make sure all maintenance tasks have been performed following the prescribed maintenance schedule (Refer to Section 7) If maintenance does not seem to solve the problem, follow the troubleshooting procedures under Section 8. CE COMPLIANCE Cosen’s CE model is designed to satisfy regulations of the Council Directive on the approximation of the laws of the Member States relating to machinery (2006/42/EC) ‐ Annex I Essential health and safety requirements relating to the design and construction of machinery. RISK ASSESSMENT Risk assessment generally takes account of intended use and foreseeable misuse, including process control and maintenance requirements. We made every effort to avoid any personal injury or equipment damage during the machine design stage. However, the operator (or other people) still needs to take precautions when handling any part of the machine that is unfamiliar and anywhere on the machine that has potential hazards (e.g. the electrical control box). 1‐10 ...
Page 20: Section 2 - General Information
INFORMATION SPECIFICATION MACHINE PARTS IDENTIFICATION FLOOR PLAN This band saw machine is designed by Cosen’s R&D engineers to provide you the following features and advantages: Safety  This machine is designed to fully protect the operator from its moving parts during cutting operation.
Page 21 SPECIFICATION Model NC Fully Automatic Horizontal Bandsaw 360 mm (14.2 in) Round 360 x 360 mm (14.2 x 14.2 in) Square Capacity 360 x 400 mm (14.2 x 15.7 in) Rectangular (H X W) W: 190 ~ 350 mm (7.5 ~ 13.8 in) Bundle Cutting H: 100 ~ 180 mm (3.9 ~ 7.1in) 20~100 m/min (66~328 ft/min)
Page 22 MACHINE PARTS IDENTIFICATION Idle Wheel Drive Wheel Front Vise Cylinder Quick Approach Bar Front Vise Bed Control Panel Cutting Pressure Control Knob Blade Descend Speed Control Knob Chip Conveyor (optional) Workbed Feed Roller Vertical Alignment Roller...
Page 23: Floor Plan
FLOOR PLAN Machine top view Machine front view...
Page 24 Machine side view...
Page 25: Section 3 - Moving & Installation
Section 3 MOVING & INSTALLATION LOCATION & ENVIRONMENT UNPACKING & INSPECTING LIFTING REMOVING SHIPPING BRACKET CLEANING INSTALLING RELOCATING LOCATION & ENVIRONMENT For your safety, please read all information regarding installation before proceeding. Install your machine in a place satisfying all of the following conditions: Space:  Leave enough free space around the machine for loading work and unloading cut‐off pieces as well as for maintenance and inspection. Refer to Section 1 Description for machine dimensions and floor space. Environment:  Well lighted (500 lumen at minimum).  Floor kept dry at all times in order to prevent operators from slipping.  Away from direct exposure to the sunlight  Room temperature between 5˚C to 40˚C. Humidity level kept at 30  ~95%“(without condensation) to avoid dew on electric  installation and machine.  Away from vibration of other machines  Away from powders or dusts emitted from other machines ...
Page 26: Unpacking & Inspecting
UNPACKING & INSPECTING  Unpack your machine carefully to avoid damage to machine parts or surfaces.  Upon arrival of your new band saw, please confirm that your machine is the correct model and it comes in the same specification you ordered by checking the model plate on the machine base.  It is also imperative that a thorough inspection be undertaken to check for any damage that could have occurred during shipping. Pay special attention to machine surface, equipments furnished and the electrical and hydraulic systems for damaged cords, hoses and fluid leaks.  In the event of damage caused during shipping, please contact your dealer and consult about filing a damage claim with the carrier.  Your machine comes in with a set of tools for you to maintain the machine. The accessories furnished are as follows: 1. Tool box 1 pc 2. Grease gun 1 pc 3. Screwdriver (+, ‐) 2 pcs 4. Open‐ended spanner ...
Page 27: Lifting
LIFTING When moving the machine, we strongly suggest you choose any one of the methods described below to move your machine. 1. Use a crane Move the machine to its location by using a crane and a wire rope sling that can fully withstand the weight of the machine (refer to machine specification under Section 1 Description).  Machine lifting is likely to damage the machine if not performed properly. Warning: You must have a qualified crane operator to perform the job.  You must use tools and equipment with the proper tensile strength and use proper method when moving your machine.  Apply the wire rope sling to the lifting hooks on the four ends of the machine.  Slowly lift the machine. Be sure to protect the machine from impact or shock during this procedure. Also watch out your own fingers and feet to avoid injuries.  Keep the machine well balanced during lifting process and make sure the wire rope does not interfere with the saw frame.  When you work together with more than two people, it is best to keep constant verbal ...
Page 28 2. Use a forklift Most users choose this method to move their machine because it is easy to set up. Make sure that the lifting rod can fully withstand the weight of the machine. (Refer to Section 2 – General Information for Specifications)  Machine lifting is likely to damage the machine if not performed properly. You must have a qualified forklift operator to perform the job.  You must apply proper forklift technique to avoid damage to the machine. Make sure the forks are able to reach in at least 2/3 of the machine depth.  You must keep the machine balanced at all times. Make sure the forks are centered before use. Refer to Picture: Lifting Points for exact locations. ...
Page 29: Picture: Lifting Points
Picture: Lifting Points Minimum weight capacity for each lifting rod: 3 ton Total number of lifting rod required: 2 3‐5...
Page 30: Removing Shipping Bracket
Retain this bracket so that it can be used again in the event that your machine must be relocated. CLEANING After the machine has been placed at the designated position, remove the rust‐preventive grease with wiping cloth dampened with cleaning oil or kerosene. Apply machine oil to machine surfaces that are prone to rust. Do not remove the rust‐preventive grease with a metal scraper and do not wipe the painted surfaces with solvent as doing so would damage surface paint. INSTALLING Cosen’s bandsaw machine is relatively easy to install. Follow these six easy steps to install your machine. Connect Leveling & Supply Supply (Installing electric anchoring hydraulic oil cutting fluid roller table) power ...
Page 31: Supplying Coolant
remaining in the tank. Always check the coolant supply before starting the machine. If the coolant pump is started without enough coolant supply in the tank, the pump and its drive motor may be damaged. Refer to specification chart under Section 1 Description for tank capacity. Consult your coolant supplier for bandsaw use regarding coolant type and mix ratio. Connecting electric power Have a qualified electrician make the electrical connections. If the power supply voltage is different from the transformer and motor connection voltage shown on the label attached to the electrical compartment of the machine, contact COSEN or your agent immediately. Connect to power supply independently and directly. Avoid using the same power supply with electric spark machines such as electric welder. Unstable electric tension may affect your machine’s electric installation from working properly. Ground the machine with an independent grounding conductor. Supply voltage: 90 ‐ 110  of nominal supply voltage. Source frequency: 99  ‐ 101  of nominal frequency. Refer to the specification chart under Section 1 for total electric power consumption of the motors and make sure your shop circuit breaker is capable of this consumption amount. Also use a power supply cable of proper size to suit the power supply voltage. 3‐7...
Page 32 Turn off the shop circuit breaker. Make sure the machine circuit breaker switch on the electrical compartment door is turned to OFF. Remove the screw securing the electrical compartment and then open the door. Pull the power supply cable and grounding conductor through the power supply inlet into the electrical compartment. (Shown right) Connect the power supply cable to the circuit breaker (N.F.B.) to the R, S and T terminals, and connect the ground cable to the E terminal. Close the compartment door and fasten the screw Power Supply Inlet back. Turn on the shop circuit breaker and then turn the machine circuit breaker switch to ON. The Power Indicator on the control panel will come on. Pull to unlock the Emergency Stop button and press the hydraulic ON button to start the hydraulic motor. Make sure the sawing area is clear of any objects. Start the blade and check the blade rotation. If the electrical connections are made correctly, the blade should run in a counterclockwise direction. If not, shut the hydraulics off, turn off the machine as well as the shop circuit breaker. Then swap the power the power cable conductors connected to R and T terminals. Repeat step 6 to 9 to ensure the electrical connections are in the right order. Leveling Place spirit level on the vise slide plates and the work feed table. ...
Page 33: Installing Roller Table (Optional)
Anchoring the machine Normally there is no need to anchor the machine. If the machine is likely to vibrate, fix the machine to the floor with anchor bolts. Shock absorption steel plates are provided and can be placed under each leveling bolt to prevent their sinking into the concrete floor. Installing roller table (optional) The roller table is used to support long material at the rear and/or the front of the machine. If you have ordered the optional roller table for cutting long material, position it before or behind the machine. Level the roller table and the stand with the Adjust bolts machine by adjusting the leveling bolts. Installing Fire Control Device Install a fire extinguisher or any other fire control device in the shop in case a fire breaks out. RELOCATING We recommend you follow these procedures when relocating or shipping your machine to other place: ...
Page 34: Section 4 - Operating Instructions
Section 4 OPERATING INSTRUCTIONS SAFETY PRECAUTIONS BEFORE OPERATING CONTROL PANEL STANDARD ACCESSORIES OPTIONAL ACCESSORIES UNROLLING & INSTALLING THE BLADE ADJUSTING WIRE BRUSH ADJUSTING SAW ARM ADJUSTING BLADE SPEED BREAKING‐IN THE BLADE PLACING WORKPIECE ONTO WORKBED POSITIONING WORKPIECE FOR CUTTING ADJUSTING COOLANT FLOW TEST‐RUNNING THE MACHINE CUTTING OPERATION USING TOP CLAMP FOR BUNDLE CUTTING TERMINATING A CUTTING OPERATION 4‐1 ...
Page 35: Safety Precautions
SAFETY PRECAUTIONS For your safety, please read and understand the instruction manual before you operate the machine. The operator should always follow these safety guidelines:  The machine should only be used for its designated purpose.  Do not wear gloves, neckties, jewelry or loose clothing/hair while operating the machine.  For eye protection, always wear protective safety glasses.  Check the blade tension and adjust blade guides before starting the machine.  Use auxiliary clamping or supporting devices to fix material in place before cutting long workpieces. Always make sure the material is clamped firmly in place before starting to cut.  Do not remove jammed or cut‐off pieces until the blade has come to a full stop.  Keep fingers away from the path of the blade.  Protection devices should be in place at all times. For your own safety, never remove these devices.  Disconnect machine from the power source before making repairs or adjustments.  Wear protection gloves only when changing the blade.  Do not operate the machine while under the influence of drugs, alcohol or medication.  Do not take your eyes off the machine while in operation.  Do place warning signs to mark out machine work zone and restrict entry to be staff‐only. ...
Page 36: Before Operating
BEFORE OPERATING Choosing an appropriate saw blade and using the right cutting method is essential to your cutting efficiency and safety. Select a suitable saw blade and cutting method based on your work material and job requirements e.g. cutting accuracy, cutting speed, economic concern, and safety control. Wet cutting If you choose dry cutting or low‐speed cutting, the chips may accumulate in machine parts and may cause operation failure or insulation malfunction. We suggest you choose wet cutting to avoid machine damage. Cutting unknown materials Before cutting an unknown material, consult the material supplier, burn a small amount of chips from the material in a safe place, or follow any other procedure to check if the material is flammable. Never take your eyes off the machine while in operation. Cutting fluid For cooling and lubrication purpose, we recommend you use water‐soluble cutting fluids. The following table lists out its pros and cons for your reference. Pro Con  Have a high cooling effect  Remove machine paint  Not flammable  Lose its rust protection effect if  Economical deteriorated  Does not require cleaning of the cut  Tend to create foam  Subject to decay products ...
Page 37: Control Panel
CONTROL PANEL The control panel is located on the top of the electrical box. It includes the following function: power system, hydraulic system, cooling system and the human‐machine–interface (HMI). The operator must fully understand the function of each switch and button before operating the machine. No. Name No. Name 1 Emergency stop button 7 Front vise clamp/open selector switch 2 Power indicator lamp 8 Rear vise clamp/open selector switch Hydraulic start/stop buttons (with built‐ 3 9 Feed forward/backward selector switch in light) (for CE model only) Saw blade start/stop buttons (with 4 10 HMI touch screen built‐in light) (for CE model only) Blade speed control knob (Inactive; moved 5 Saw bow down button 11 into HMI system) 6 ...
Page 38: Control Buttons
Control Buttons 1. Emergency stop button Press this button to stop the machine in an emergency. When the button is pressed, it brings the machine to a full stop. The button locks when pressed. In order to unlock it, please turn the button clockwise. 2. Power indicator lamp When the lamp is on, it indicates the power to the machine is turned on. 3. Hydraulic start/stop buttons (with built‐in light) (for CE model only) Press green button to start the hydraulic motor. (The button lights up when pressed.) Press red button to stop the hydraulic motor. (The button lights off when pressed.) When the emergency stop button is pressed, the hydraulic motor will be shut off. When the hydraulic motor is turned on, the chip conveyor will start running at the same time. Please take cautions and keep your hands away from chip conveyor. 4. Saw blade start/stop buttons (with built‐in light) (for CE model only) Press green button to start the blade drive motor. (The button lights up when pressed.) Press red button to stop the blade drive motor. (The button lights off when pressed.) ...
Page 39 When this switch is turned to the “closed” position (to the right), the front vises will continue to close until the operator lets go of the switch or when the vises are fully clamped. Hold the switch until the desired vise position is reached. This selector switch only works when the machine is switched to manual mode “ ”. 8. Rear vise clamp/open selector switch When this switch is turned to the “open” position (to the left), the rear vises will continue to open until the operator lets go of the switch. Hold the switch until the desired vise position is reached. When this switch is turned to the “closed” position (to the right), the rear vises will continue to close until the operator lets go of the switch or when the vises are fully clamped. Hold the switch until the desired vise position is reached. This selector switch only works when the machine is switched to manual mode “ ”. 9. Feed forward/backward selector switch When the selector switch is turned to the “forward” position (to the lower left), the feeding workbed will move forward, feeding material forward. Press and hold the button to feed forward. As soon as the button is released, the feeding workbed will stop moving forward. When the selector switch is turned to the “backward” position (to the upper left), the feeding workbed will move backward, feeding material backward. Press and hold the button to feed backward. As soon as the button is released, the feeding workbed will stop moving backward. This selector switch only works when the machine is switched to manual mode “ ”. This selector switch is only in function when the quick approach bar is touching the upper limit switch AND when either of the front and rear vises are unclamped. After the blade motor starts running, the function of rear vise is disabled due to safety concerns. 10. HMI touch screen Please refer to later section for detailed introduction. 11. Blade speed control knob (Inactive; moved into HMI system) Blade speed is controlled by the inverter located under the workbed. This button is now inactive as the blade control function has been included in the HMI system. ...
Page 40 Blade descend pressure and speed control panel The part of control panel is where cutting pressure and saw bow descend speed can be adjusted. 1. Cutting pressure control knob  This pressure control knob is used to adjust the cutting pressure of the blade.  Turning the knob clockwise increases the cutting pressure.  To obtain a good cutting result, choose the right cutting pressure by turning the knob until it points to your material on the color chart. 2. Blade descend speed control knob  This knob is used to adjust the descend speed of the saw blade.  Turning the knob clockwise increases the blade descend speed.  Blade descend speed is a determining factor to a good cutting time and quality cutoff surface.  Set the blade descend speed in accordance with the cutting pressure control knob.  Also commonly known as the flow control Cutting pressure and speed control panel valve. Human‐machine‐interface (HMI) touch screen ...
Page 41 Item Range Ambient temperature 5℃ ~ 50℃ Temperature for safe ‐10℃ ~ 60℃ operation Ambient humidity 30%~85% RH (No condensation) Connection RS422 MMI port Environment No condensation and rust Startup Screen After the power is turned on, Cosen’s logo will appear as the startup screen, followed by the main operation menu.. Main control menu The main control menu includes some operating button that were used on the control panel of the earlier machines. Some convenient functions are added to the page for the operator to better understand the features of the machine. Setting the parameters shown on the screen requires a gentle touch of the finger. You can also look up the parameters or make changes while in the middle of a cut. 4‐8 ...
Page 42 Refer to the table below for descriptions of each function. No Item Function Description Work light ON/OFF Press this button to turn on the work light. 1 A solid yellow light bulb icon indicates the lamp has been turned on. Press again to turn off the work light. Material retract 2mm When this function is turned on, the machine will 2 ON/OFF retract the material for 2mm after completing each cut before the blade rises from its lowest position. A solid yellow icon indicates the Material retract 2mm mode has been turned on. Coolant ON/OFF Press this button to turn on the coolant pump. 3 A solid yellow faucet icon indicates the coolant pump has been turned on. Press again to turn off the coolant pump. Trim cut ON/OFF : indicates the “one cut” in action, as soon as 4 it is finished, will NOT be counted into the “finished cuts,” i.e. “finished cuts” value will increase by 0. (trim cut) : indicates the “one cut” in action, as soon as it is finished, will be counted into the “finished cuts,” i.e. “finished cuts” value will increase by 1. When under AUTO mode and before proceeding with your automatic cutting jobs, select ...
Page 43 No Item Function Description function) is completed, trim cut function will be automatically turned back to OFF, showing . After the first cut begins, you may still change your selection between and before the saw bow has descended to its lowest point. The cutting material width must be OVER 30mm to be able to use automatic first cut properly. AUTO/Manual mode Use this button to switch between automatic and 5 manual mode.  AUTO mode ( ): used to automatically perform continuous cutting jobs. When switched to the AUTO mode, the machine will automatically operate according to the preset parameters.  Manual mode ( ): used to perform individual cutting job. When switched to the Manual mode, you can execute each individual function. Trim Cut ‐ When the machine is started up first under the Manual mode and then switched to the AUTO mode, whether the first cut (trim cut) will be counted into finished cuts or not will depend on how the trim cut ON/OFF switch is selected. Switching from AUTO mode to Manual mode during continuous cutting jobs, the ...
Page 44 No Item Function Description a single work piece.  Switch to bundle cutting mode ( ) to cut a stack of work pieces. When under bundle cutting mode, the feeding vise must be touching the front limit switch for the blade to be able to start. Slow/Fast material Used only when under Manual mode. feeding mode When the slow material feeding mode (snail icon) is turned on, the material feeding speed will dramatically reduce to help you position the work piece precisely. Automatic first cut This selection button works with the automatic function ON/OFF cutting mode. When under AUTO mode and before proceeding with your automatic cutting jobs, select if you wish the machine to automatically execute the first cut of the cutting jobs you programmed in the system. (For cutting program setting, refer to introduction under “Cutting Parameter Setup ‐ Page 3”) With the first cut function, simply clamp the material with the rear vise with about 60~70 mm sticking out toward the blade, turn on the first cut function and switch to automatic mode, then the machine will automatically feed the material to the right position to execute the first cut, followed by the rest of the programmed cutting jobs. The first cut is also counted into finished cuts. ...
Page 45 No Item Function Description Saw blade middle Indicates that the saw blade has descended to 11 indicator the position of the middle limit switch. When activated, the saw blade icon will turn solid white. Due to safety considerations, the shuttle bed feeding/retracting function will be temporarily disabled while the saw blade middle indicator is activated. Saw bow down Indicates that a cut is completed and the saw 12 indicator bow is at its lowest position. When the blade completes each cut and triggers the lower limit switch, the saw blade icon will turn solid white. Rear vise status Indicates if the rear vises have clamped and 13 indicator secured the workpiece. When the rear vises have secured the workpiece, the clamping vise icon on the right will turn solid white. Otherwise, the unclamping vise icon on the left will be in solid green. Front vise status Indicates if the front vises have clamped and 14 indicator ...
Page 46 No Item Function Description Blade motor amp draw Displays the motor amperage drawn. With this 18 information the operator will be able to optimize cutting speed and blade usage. Feeding length display Displays current feeding length while the 19 material is being fed. Error display Displays error messages in the order of 20 occurrences; press the message to clear the (yellow highlight) messages. Error messages must be cleared for the machine to continue to operate normally. System parameter Press this button to set up system parameters. 21 setting Password is required. All parameters have been set up by the manufacturer. In order to prevent random change from being made to these parameters and affect cutting precision and machine life, this function is protected with a set of password. Cutting program Press this button to directly enter the cutting job 22 setting ...
Page 47 Cutting program setup At any given time, press to quickly jump to the cutting program setup page (the same as page 3 of the cutting status display and setup page). As shown below, this page is where the operator program automatic cutting by setting cutting length and quantity under each job. A total of 100 cutting jobs can be set and performed under the automatic mode. Function Item Description Length column Cutting length setup Press these buttons to set each respective cutting length in the preset length unit (mm or inch). A number key pad will pop out. If any preset cutting program data is altered during an automatic operation, the cutting result will be changed. Quantity column Cutting quantity setup Press these buttons to set each respective cutting quantity. A number key pad will pop out. If any preset cutting program data is altered during an automatic operation, the cutting result will be changed. This column displays the number of finished cuts for Cut Finished column Cutoff quantity display each job. Key in the number of the job you wish to execute first Starting cutting job under automatic mode. setup The starting job can be set to any number and does not need to be job “0.” Both “Starts job” and “End job” need to be set for an automatic operation to be started. Ending cutting job setup Key in the number of the job you wish to execute last ...
Page 48 Item Function Description Clear finished cuts data Reset all Cut Finished data by pressing this button for three seconds. (Same as “Cut Piece Reset” described earlier.) If this key is pressed during an automatic operation, the finished cut data of the current job will be reset and recalculated. Cutting status display & setup When cutting is in operation, press to enter cutting status display and setup page. Page 1: cutting status display No Item Function Description Blade height display Displays current blade height. Displays current feeding Feeding length display length while the material is being fed. Blade downfeed speed display Displays the current blade descending speed. Blade speed display Displays current blade speed. ...
Page 49 No Item Function Description Blade motor amp draw Displays the motor amperage drawn. With this information the operator will be able to optimize cutting speed and blade usage. Cutting rate display Displays the current cutting rate. Current job number display Displays the number of the current cutting job. Preset quantity display Displays the preset quantity of the current cutting job. Finished quantity display Displays the number of cuts finished. Press this button to enter the HP (horsepower) monitor screen for V_Drive, which is an optional accessory for enhancing cutting efficiency and reducing cutting vibrations. Return to the main control menu. 4‐16 ...
Page 50 Page 2: cutting status setup Return to the main control menu. Return to the previous setup page. Go to next setup page. Error message display. Press to clear. No Item Function Description Press this button to set material width. With material Material width setting width, the system can automatically calculate cutting rate.  Left: Positive deviation Blade deviation setting  Right: Negative deviation ...
Page 51 No Item Function Description Blade lifetime display Displays the total usage time of the blade, if the “Blade life Reset” is pressed, the blade usage time will be recalculated. High/low gear selection Press this key to switch between low and high gears for the drive belt. switch  L Gear：indicates the drive belt is at low gear.  H Gear：indicates the drive belt is at high gear. Maximum blade speed: On L Gear: 72 M/min On H Gear: 100 M/min Not shown if the machine comes without this option. Reset all Cut Finished data by pressing this button for Clear finished cuts data three seconds. If you start a new set of program without clearing cutoff data from previous job, the first cut (trim cut) will be skipped as the second program is deemed as the succeeding part of the previous program. If this key is pressed during an automatic operation, the finished cut data of the current job will be reset and recalculated. Press this key for three seconds to clear all preset ...
Page 52 PLC Monitor  Shows all signals of the PLC system. Error report Page 1 – error report  Lists a historical report of the errors and the time of occurrence.  Press Home to return to the main control menu.  Press Next to go to the troubleshooting support page. Page 2 – troubleshooting  Provides suggestions on troubleshooting. 6 pages in total.  Also refer to below table for error codes, descriptions and solutions.  Press HOME to return to the main control menu.  Press NEXT to go to the troubleshooting support page. 4‐19 ...
Page 53 Error Error Description Solution Code M300 Front vises not clamping Check if the queen valve works M301 Rear vises not clamping Check if the queen valve works M303 Lower limit switch error Check if the lower limit switch works M304 Hydraulic motor not starting Check if the hydraulic motor works M306 Broken blade detected 1. Check if the speed switch works 2. Check if the blade is broken M308 Left safety door abnormal 1. Check if the left safety door is shut properly 2. Check if the left safety door limit switch works M309 Right safety door abnormal 1. Check if the right safety door is hut properly 2. Check if the right safety door limit switch works M312 Quick approach bar abnormal Check if the quick approach limit switch works M313 OL1 abnormal Check if the blade motor overload relay has tripped M314 OL2 abnormal Check if the hydraulic motor overload relay has tripped M315 OL3 abnormal Check if the coolant pump motor overload relay has tripped M316 ...
Page 54: Standard Accessories
STANDARD ACCESSORIES Blade tension device  This blade tension device equipped with hydraulic cylinder provides appropriate tension to the saw blade.  To tighten the saw blade, turn the selector to .  Upon saw blade breakage, the safety device will activate and automatically stop all machine operation.  To change the blade, turn the handle to to release saw blade tension. Never adjust blade tension while the blade is running. The blade tension pressure meter is controlled by system pressure. Blade tension has been configured at time of manufacturing. Do not make random changes as it will affect machine performance.  Standard blade pressure: 35 ~ 40 kg/cm2  Standard blade tension: 2300 ~ 2400 kg/cm2 Blade speed/motion detector  Besides detecting the blade speed, the speed/motion detector also functions as a safety device.  The speed/motion detector protects operators and the machine by preventing blade overloads and consequent damages if a saw blade breaks or skids.  Once blade breakage or slippage is detected, the drive wheel will stop in 10 seconds. ...
Page 55 Quick Approach Device This device is used to allow the saw blade to quickly descend to just above the workpiece. As the quick approach bar touches the material top, the saw bow’s descending speed shifts back to cutting mode, which can be changed by adjusting the blade descend speed control valve based on the material to be cut. Split Front Vise The spilt vises are a clever design to make sure your workpiece is tightly clamped by the two vises from both sides of the blade, maximizing stability and cutting precision. Double Retracting Rear Vise The rear fixed vise has a built‐in hydraulic cylinder. When rear vises start actions, the rear fixed vise will always act ahead of the rear Rear movable vise movable vise. Rear fixed vise Gear reducer The specially designed gear reducer can work toward your preset blade speed and torque. Please refer to Chapter 8 for information on maintenance. 4‐22 ...
Page 56 Wire Brush Assembly The wire brush is driven by the main motor to remove the metal chips on the saw blade teeth so that blade life can be extended. Keep hands away from the transmission shaft and the brush while the wire brush is running. Turn off the hydraulic motor or the main power switch before performing maintenance or cleaning on the wire brush drive system. Work light The work light installed on top of the saw is a useful tool when supplementary lighting is needed for material alignment or operation. Height Decoder With this device installed on the left column, the operator can input work piece width via HMI touch panel. When cutting begins and the blade starts to descend, the panel will display the current blade ...
Page 57: Optional Accessories
Vibration Damper Installed in the left guide arm, the anti‐vibration roller set reduces high frequency noise when the saw blade is cutting heavy material producing noise. Coolant Pump The coolant pump supplies coolant to cool off cutting temperatures during cutting. Also, it can be used to wash off chips. OPTIONAL ACCESSORIES Vise Pressure Regulator  This adjustment valve is used to control vise pressure.  Adjust vise pressure based on the material of your workpiece. Pressure  When cutting pipes or soft materials, reduce vise pressure adjusting to prevent exerted pressure from damaging the workpiece Pressure shape or exterior. valve gauge Do not adjust vise pressure at any time during cutting. Vise pressure should never be lower than 8 kg/cm Chip conveyor Chip conveyor is a spiral device to bring chips out during cutting. As a regular maintenance, remove the chip conveyor ...
Page 58 Hydraulic top clamps The top clamp device composed of two clamps is installed on top of the front and rear vises before executing bundle cutting. Blade Deviation Detector This device detects blade deviation. If the blade deviates beyond the preset range, the machine will stop automatically. When this device is installed, the cutting width will be reduced. The blade deviation detected value and preset values are displayed on the control panel screen. Deviation Detector Calibration Procedure How to Adjust 1. Unclamp the tungsten carbide inserts. 2. Loosen the nut (M8 x P1.25). 接近感測器 3. Adjust the nut until the blade deviation value shown the display returns to zero. 4. Tighten the nut. 5. Clamp the tungsten carbide inserts. 鋼條擺臂 How to Check 1. When the carbide inserts are relieved, the distance between the saw blade and the proximity sensor set should be about 4 mm. 中心軸...
Page 59: Unrolling & Installing The Blade
2M Roller Table The optional 2M roller table supports the work material and ensures the material is fed in smoothly. UNROLLING & INSTALLING THE BLADE Always wear leather gloves and protection glasses when handling a blade. Unrolling the blade Please follow the procedures illustrated below. 4‐26 ...
Page 60 Installing a new blade Step 1 ‐ Select the most suitable saw blade for your workpiece considering the size, shape and material. Step 2 ‐ Turn on the machine power by switching to ON and turn on the hydraulic system. Step 3 – Switch to manual ( ) mode. Step 4 ‐ Press the saw bow up button and elevate the saw bow until the blade is slightly above the top of vises with enough room for blade changing. Step 5 – Unclamp the carbide inserts. Step 6 ‐ Turn the tension controller handle from “ ” to “ ” position to release tension. The idle wheel will then move slightly toward the direction of the drive wheel. Step 7 ‐ Open the idle and drive wheel covers. Step 8 – Loosen the wire brush assembly lock nuts and move the wire brush away from the blade. Refer below ADJUSTING WIRE BRUSH. Step 9 ‐ Pull down the worn saw blade from the carbide inserts, wire brush assembly and from the two wheels. Roll up the used blade and place it at a safe place. Step 10 ‐ If necessary, clean the blade guide rollers before installing a new saw blade. Step 11 ‐ Insert the new blade into the left and right tungsten carbide inserts. The back and the sides of the blade need to be touching the inserts as well as the adjacent rollers. Step 12 ‐ Insert the blade into the left and right tungsten carbide inserts. The back and the sides of the blade need to be touching the inserts as well as the adjacent rollers. Before changing the blade, make note of the direction the blade is running and the blade teeth is facing. Step 13 ‐ Place the blade to the drive wheel and press the back of the blade against the flange of the drive wheel. Step 14 ‐ Make sure the back of the blade is also pressed against the flange of the idle wheel. Step 15 ‐ Turn the tension controller handle to [ ] position to obtain blade tension. Step 16 ‐ Make sure the sides of the blade are in close contact with the carbide inserts and then tighten the left and right carbide inserts. Step 17 – Gently close the idle and drive wheel covers. Step 18 ‐ Press the saw blade start button to start the blade. Allow the blade to run for a few rotations then press the saw bow up button to elevate the saw bow. Open the wheel covers and make sure the blade has not fallen off the drive and idle wheels. If the blade has shifted, follow the same procedure to reinstall the blade again. Step 19 ‐ Adjust wire brush to a proper position. ...
Page 61: Adjusting Wire Brush
ADJUSTING WIRE BRUSH Follow these steps to adjust wire brush to appropriate position: Step 1 – Loosen the wire brush adjusting screw (indicated A in below picture) and lower wire brush via adjusting handle. Step 2 – Loosen the wire brush lock nut (indicated B in below picture), remove the old worn wire brush and replace with a new one. Tighten the wire brush lock nut. Step 3 – Make brush move up / down via the adjusting handle until it makes proper contact with the saw blade (also see below illustration). Step 4 – Tighten the wire brush adjusting screw. Proper Improper ADJUSTING SAW ARM Adjust the blade guide (guide arm) position based on the size of your workpiece: Step 1 – Loosen the carbide inserts by pulling down the lock handle at the left and right blade guide brackets. Step 2 – Adjust the guide arm to a position suitable for your workpiece size. The left guide arm rides ...
Page 62: Adjusting Blade Speed
ADJUSTING BLADE SPEED Step 1 – Set the flow control to “0” position. Step 2 – Press the saw blade start button to start the blade. Step 3 – Via HMI touch screen, you can set the blade speed by directly keying in the value or use the acceleration/deceleration button to control the speed. The blade speed should be adjusted based on the size and the material of the workpiece. BREAKING‐IN THE BLADE When a new saw blade is used, be sure to first break in the blade before using it for actual, extended operation. Failure to break in the blade will result in less than optimum efficiency. To perform this break‐in operation, the following instructions should be followed: Step 1 ‐ Reduce the blade speed to one‐half of its normal setting. Step 2 ‐ Lengthen the cutting time to 2‐3 times of what is normally required. Step 3 ‐ The complete break‐in operation requires cutting on a 645 mm2 (25.4 square inches) section for 5 times. Step 4 ‐ After the break‐in operation is completed, set all parameters back to normal settings. PLACING WORKPIECE ONTO WORKBED Step 1 – Press the saw bow up button and elevate the saw bow until it reaches to its highest point. Step 2 – Press the front vise open and rear vise open buttons to open vises. Step 3 – Loosen the vertical roller lock handles and fully open the vertical rollers. Step 4 – Carefully place the workpiece onto the work feed table to where it extends approximately 70~100 mm (2.75~3.9 inch) beyond the rear vise toward the front vise. 4‐29 ...
Page 63: Positioning Workpiece For Cutting
POSITIONING WORKPIECE FOR CUTTING A. Without using AUTOMATIC FIRST CUT FUNCTION Follow these steps to position your workpiece: Step Action After the workpiece has been properly placed on the workbed, press rear vises clamp material the rear vise clamp button until the workpiece is securely clamped. Move the vertical alignment rollers toward workpiece until it stands align vertical rollers against the workpiece. Lock the vertical alignment rollers by tightening the lock handles. Press the feed forward button until the rear vise touches the front feed material forward limit switch. Press the front vise clamp button until the workpiece is securely front vises clamp material clamped. Press the rear vise open button. rear vises retract to clamp material again Press the feed backward button until the rear vises reach back limit switch. Press the rear vise clamp button until the workpiece is securely clamped again. Press the front vise open button and the rear vise clamp button again.
Page 64: Using Automatic First Cut Function
B. Using AUTOMATIC FIRST CUT FUNCTION The cutting material width must be OVER 30mm to be able to use automatic first cut properly. Follow these steps to position your workpiece and get it ready for an automatic cutting job using the automatic first cut function. Step Action After the workpiece has been properly placed on the workbed (with rear vises clamp material about 70‐100 mm sticking out past the rear vises toward the front vises, leaving enough room before the front vises), press the rear vise clamp button until the workpiece is securely clamped. Move the vertical alignment rollers toward workpiece until it stands align vertical rollers against the workpiece. Lock the vertical alignment rollers by tightening the lock handles. Press the front vise clamp button until the front vises are clamped 3 close front vises together. Via the HMI touch screen, making the following settings: program cutting jobs  Set your desired length and quantity for the first step of your cutting job. If you wish to apply the first cut as trim‐cut, however, set quantity to 1 and remember to turn on trim‐cut function (+0) so it will not be counted into finished cuts.  Program the rest of your cutting jobs if any. Remember to set your starting step and ending step accordingly. Via the HMI touch screen, turn on the automatic first cut function and 5 turn on automatic first cut switch to automatic cutting mode. function ...
Page 65: Adjusting Coolant Flow
ADJUSTING COOLANT FLOW A total of four coolant flow control valves are in place to provide lubrication, cooling and cleaning for this machine. These valves control coolant flow amount to:  the left blade guide,  the right blade guide  the coolant nozzle and,  to the wire brush To adjust the coolant flow, follow these steps: Step 1 – Press the coolant ON button to start the coolant pump. Step 2 – Use the coolant flow control valves (shown below) to adjust the amount of fluid flowing to the cutting area. (For left blade guide) (For right blade guide) (For coolant nozzle & wire brush) Adjust the flow amount if you observe the following changes to the chips generated from cutting. If the chips are sharp and curved, increase the coolant flow amount. If the chips are granulated, decrease the coolant flow amount. 4‐32 ...
Page 66: Test-Running The Machine
TEST‐RUNNING THE MACHINE Test‐running this machine can ensure good machine performance in the future. We suggest you run the following tests on the machine before first use: Testing machine performance: Turn on the power and run a basic performance test after you finish installing the machine. Follow these steps to test machine performance: Step 1 – Disassemble shipping brackets and bolts. Step 2 – Install roller table (optional). Step 3 – Turn on the relay switch in the control box. Step 4 – Elevate the saw bow. (If your coolant pump is in reverse and the machine cannot run, please change the electrical phase.) Step 5 – After the saw bow ascends, extend the quick approach device. Step 6 – Remove the rust‐prevention grease with cleaning oil or kerosene. Step 7 – Start the coolant pump. Step 8 – Test these functions under manual mode:  vise clamping/unclamping  saw bow ascending/descending  feeding forward and backward. ...
Page 67: Cutting Operation
CUTTING OPERATION Step 1 – Check before you cut  Power: Check the voltage and frequency of your power source.  Coolant: Check if you have sufficient coolant in the tank.  Hydraulic: Check if you have sufficient (at least two‐thirds or higher) hydraulic oil.  Workbed: Check if there is any object on the feeding bed that may cause interference.  Blade: Check the blade teeth and make sure there is no worn out teeth along the blade.  Light: Check the work lamp or laser light (optional) and make sure there is sufficient lighting.  Roller: Check all the rollers on the front and rear workbed can roll smoothly.  Saw bow: Check the saw bow to see if it can be elevated and lowered smoothly Step 2 – Place your workpiece onto the workbed manually or by using a lifting tool e.g. a crane. Before loading, make sure the vises are opened wide enough and the blade is raised high enough to allow enough clearance for the workpiece. When loading, take extra care not to have the workpiece bump into the blade. Step 3 – Position your workpiece. Decide to use the automatic first cut function or not. Refer above POSITIONING WORKPIECE FOR CUTTING. With the automatic first cut function, the machine can automatically detect material front end and feed it exactly to where it needs to be for your programmed jobs. The cutting material width must be OVER 30mm to be able to use automatic first cut properly. Step 4 – Clamp the workpiece. Step 5 – Turn the cutting pressure control knob to adjust blade cutting pressure according to the material. Step 6 – Adjust blade descend speed control knob to obtain a suitable blade descend speed for your material. Step 7 – Start running the blade. Before you start cutting, check again that there is no other object in the cutting area. Step 8 – While the blade descends, adjust the blade speed if necessary. You can do so by pressing the acceleration and deceleration buttons on the HMI touch screen. The blade speed is displayed on the HMI touch screen. Step 9 – Select the proper cutting condition according to different material. Step 10 – After the entire cutting job is completed, elevate the saw bow to the top and open the vises ...
Page 68: Using Top Clamp For Bundle Cutting
USING TOP CLAMP FOR BUNDLE CUTTING Installing top clamp To perform bundle cutting, use the top clamps and take the following installation procedures. Step 1 – Install stud bolts on the front and rear vises and position the top clamp. Lock nuts Stud bolt Step 2 – Connect the top clamp hoses to the pressure joints on the vise hydraulic cylinders. Pressure joints Step 3 – Tie the workpiece to prevent cut pieces from scattering across the workbed. Position the workpiece for bundle cutting. Note the allowable clamping width and height. (Refer to Section 2 – General Information, Specifications) Proper and improper stacking of workpieces Proper Improper Step 4 – Align the top clamp cylinders with the center of the workpiece and tighten the lock nuts. Step 5 – Turn the top clamp handles so that the clearance between the top clamp jaw and the top of the bundled workpiece is within 5 to 10 mm ( 0.2 ~ 0.4 in). Step 6 – Press . Single/Bundle cutting mode button and switch to bundle cutting mode 4‐35 ...
Page 69: Terminating A Cutting Operation
Step 7 – For subsequent cutting procedures, refer to the cutting instructions above. Uninstalling top clamp Follow these steps to uninstall top clamp for cutting single material: Step 1 – Disconnect the top clamp hoses. Step 2 – Loosen the lock nuts and remove the top clamp. Step 3 – Remove the stud bolts. STOP TERMINATING A CUTTING OPERATION • To terminate a cutting operation, press either the saw bow up button or the hydraulic stop button. • The saw blade will stop running when the saw bow up button is pressed. • Both the saw blade and hydraulic pump motors will stop running when the hydraulic stop button is pressed. • The machine will stop automatically when an error occurs. The error message will be shown on the screen. 4‐36 ...
Page 70: Section 5 - Electrical System
Section 5 ELECTRICAL SYSTEM ELECTRICAL CIRCUIT DIAGRAMS The following are electrical circuit diagrams of the system: Fig 5‐1 Control panel layout Fig 5‐2 Circuit board layout Fig 5‐3 Power supply layout Fig 5‐4 PLC I/O layout 5‐1...
Page 71 Fig.5‐1 Control panel layout 5‐2 ...
Page 72 Fig.5‐2 Circuit board layout 5‐3...
Page 73 Fig.5‐3 Power supply layout 5‐4 ...
Page 74 Fig.5‐4 PLC I/O layout 5‐5...
Page 75: Section 6 - Hydraulic System
Section 6 HYDRAULIC SYSTEM HYDRAULIC DIAGRAMS 6‐1...
Page 76 Fig. 6‐1 Hydraulic layout 6‐2...
Page 77: Introduction
Section 7 BAND SAW CUTTING: A PRACTICAL GUIDE INTRODUCTION SAW BLADE SELECTION SOME SAWING PRACTICES INTRODUCTION COSEN band saw machines are designed to be installed with high quality using high speed saw blades for maximizing productivity. To be able to use this kind of high performance band saw blade, the machine has to be of rugged design, has high quality saw blade guides, has sufficient motor horse power for high saw band speeds, and has to be able to apply necessary tension to the saw bands. Your COSEN machine has all these features to provide a better service for you. The saw blade is guided through the cutting area by roller guides to keep it straight as it comes off the driving wheels. The precision carbide inserted guides then holds the blade securely and accurately throughout the sawing process. The tension of the saw blade is adjusted through the tensioning device on the strong saw bow. The cutting feed and down feed pressure of the blade is regulated automatically by hydraulic regulation. SAW BLADE SELECTION The factors affecting cutting performance are: Type of material  Material size and shape  Guide spacing  Blade selection  ...
Page 78 Material and its relation to the cutting rate: Tooth spacing Tooth Set Fig. 7.1 Description of Band  Depending on the hardness of the material the cutting rate will increase or decrease. For example, it takes more time to cut stainless steel than to cut cast iron.  The surface conditions will also affect the cutting rate. If there are places on the surface on the material which are hard, a slower blade speed will be required or blade damage may result.  It will be slower to cut tubing than to cut solids, because the blade must enter the material twice, and because coolant will not follow the blade as well.  Tough or abrasive materials are much harder to cut than their machinability rating would indicate.  Tooth spacing is determined by the hardness of the material and its thickness in cross section.  Tooth set prevents the blade from binding in the cut. It may be either a "regular set" (also called a "raker set" ) or a "wavy set".  The regular or raker set is most common and consists of a pattern of one tooth to the left. Set to the right, to the left and one which is straight, or unset. This type of set is generally used where the material to be cut is uniform in size and for contour cutting.  Wavy set has groups of teeth set alternately to right and left, forming a wave‐like pattern. This reduces the stress on each individual tooth, making it suitable for cutting thin material or a variety of materials where blade changing is impractical. Wavy set is often used where tooth breakage is a problem. This is shown in Fig. 7.2 as follows: Right Straight Left Regular (raker) Set Wavy Set Fig. 7.2 The saw set ...
Page 79 Material Size and Shape: The optimum material width for a band saw blade is 1 inch wide by 0.35 thick and is about 5 inches long. Below this width tooth loading may become excessive and the cutting rate must be reduced. Above this width blade control begins to be lost, as discussed below. Since the blade "sees" only that material it is cutting, the shape of the stock being cut will also affect cutting speeds, particularly if the piece is excessively wide or if it varies in the dimensions being cut. Guide Spacing: The rigidity of the blade is a function of guide spacing, with rigidity being reduced to the third power as the distance between the guides increases. For example, with guides spaced 2 inches apart, blade deflection might be approximately 0.2. Under the same conditions, but with the guides spaced at 4 inches apart, blade deflection would be approximately 0.8. This is a much simplified version of the formula, because it does not consider band tension or guide design. It is important to recognize, for example that rollers are considered as a pivotal contact. Whereas carbide faces could be considered as anchored supports. A more complete deviation, including band tension and guide design, is included in Roark's handbook, "Formula for stress and strain". Blade selection: There are five types of blade material generally used: Hard‐back carbon  Semi‐high speed  High speed  Carbon  Electron‐welded blade  In most high speed production cutting either the semi‐high speed or the electron‐welded band are used. Electron welded blade is the best blade. But it is also the most expensive. To construct the electron‐welded blade, M‐2 tool steel is welded to the blade back. Therefore the blade is capable of very high surface speed. The semi‐high speed blade is used more in structural because it is capable of taking a great deal more abuse. The hard‐back carbon blade's teeth does not have red‐hardness but if ...
Page 80: Some Sawing Practices
A particular blade may have teeth which are too hard at the tips, causing them to break off in the material. This is most likely to happen as a result of chips wedging together in the cut. A broken tooth in the material can easily cause dulling on one side of the entire blade before it is dislodged from the cut. Blade Speed and Feed: Blade speed is generally limited by vibration and the ability to keep the blade sufficiently cool to avoid dulling the teeth. A blade which is running fast and taking a very light cut will dull quickly because the tips of the teeth will overheat from the rubbing action. If, however, we force the blade teeth deeper into the material, the blade will be less sensitive to heat, because the teeth are cutting more and rubbing less. Tooth Form and Spacing: The selection of a tooth form generally is determined by the material to be cut. There are three general factors to consider: tooth form, style or shape of the teeth; tooth spacing, the number of teeth to the inch; and tooth set, which provides clearance for the body of the blade. Three styles of tooth are shown in Fig. 7.4 below: Fig. 7.4 Three styles of tooth SOME SAWING PRACTICES Saw Pitch Selection Sawing “Rules of Thumb”: 1. The thinner the stock, the finer the saw pitch 2. The thicker the stock, the coarser the saw pitch 3. The more difficult the stock, the finer the saw pitch 4. The softer the material , the coarser the saw pitch Always have at least three teeth in contact with the material being cut. Material Size and Saw Pitch Anytime during the cutting operation, at least three teeth must be in contact with the material being cut. Figure 7.5 shows some sawing practices: 7‐4...
Page 81 SAWING PRACTICES CORRECT INCORRECT several teeth contact work teeth strike sharp edge Coarse teeth clear chips freely Teeth too fine for large solids Three or more teeth on cutting wall Coarse teeth rip on thin wall Fig. 7.5 Some sawing practices 7‐5...
Page 82 Solid Stock: STYLE up to 25 mm (1”) 25‐100mm (1‐4”) 100‐250mm (4‐10”) 8‐10 TPI 6‐8 TPI 3‐4 TPI (Teeth per inch) Structurals: STYLE up to 10 mm (3/8”) 10‐20mm (3/8‐3/4”) above 20mm (3/4”) 10‐8 TPI 8‐10 TPI 6‐8 TPI Solid Bundle: STYLE up to 20 mm (3/4”) 20‐80mm (3/4–3 1/4”) above 80mm (3 1/4”) 8 ‐ 10 TPI 2 ‐ 8 TPI 4 ‐ 6 TPI ...
Page 83: Section 8 - Maintenance & Service
Section 8 MAINTENANCE & SERVICE INTRODUCTION BASIC MAINTENANCE MAINTENANCE SCHEDULE BEFORE BEGINNING A DAY’S WORK AFTER ENDING A DAY’S WORK EVERY MONTH EVERY THREE MONTHS EVERY SIX MONTHS STORAGE CONDITIONS TERMINATING THE USE OF MACHINE OIL RECOMMENDATION FOR MAINTENANCE INTRODUCTION For the best performance and longer life of the band saw machine, a maintenance schedule is necessary. Some of the daily maintenance usually takes just a little time but will give remarkable results for the efficient and proper operation of cutting. BASIC MAINTENANCE It is always easy and takes just a little effort to do the basic maintenance. But it always turns out to be a very essential process to assure the long life and efficient operation of the machine. Most of the basic maintenance requires the operator to perform it regularly. MAINTENANCE SCHEDULE We suggest you do the maintenance on schedule. The recommended schedule includes three periods, 1.Daily maintenance. 2.Monthly maintenance. 3. Six months maintenance. 8‐1...
Page 84 Before beginning a day’s work 1. Please check the hydraulic oil level. If oil level volume is below 1/2, please add oil as necessary.(Filling up to 2/3 level is better for system operation.) 2. Please check the cutting fluid level, adding fluid as necessary. If the fluid appears contaminated or deteriorated, drain and replace it. 3. Please check the saw blade to ensure that it is properly positioned on both the drive and idle wheels. 4. Please make sure that the saw blade is properly clamped by the left and right inserts. 5. Please check the wire brush for proper contact with the saw blade. Replace the wire brush if it is worn out. After ending a day’s work Please remove saw chips and clean the machine with discharging the cutting fluid when work has been completed. Do not discharge cutting fluid while the saw blade is operating because it will cause severe injury on operator’s hand. Be sure the saw blade is fully stop, it will be performed after working inspection. Every month Please apply grease to the following points: 1. Idle wheel 2. Drive wheel 3. Blade tension device idle wheel ...
Page 85 Every six months 1.Clean the filter of the cutting fluid. 2.Replace the transmission oil for every half of a year(or 1200 hours). Check the sight gauge to ascertain oil fill cap the transmission level. oil level gauge oil level gauge Recommended TRANSMISSION OIL hydraulic tank  Omala oil HD220  Mobil comp 632 600W Cylinder oil 3.Replace the hydraulic oil. oil drain valve Recommended HYDRAULIC OIL  Shell Tellus 27  Mobil DTE OIL light Hydraulic28 STORAGE CONDITIONS Generally, this machine will be stored on the following conditions in future: (1) Turn off the power. (2) Ambient temperature: 5℃ ~ 40℃ (3) ...
Page 86 OIL RECOMMENDATION FOR MAINTENANCE Item Method Revolution Suggest oil Dovetail guide Keep grease covered. Antirust. Daily Shell R2 Roller bearing Sweep clean and oil with lubricant. Daily SEA #10 Bed roller / surface Sweep clean and oil with lubricant. Daily SEA #10 Nipples of bearing Use grease gun, but not excess. Monthly Shell R2 Blade tension device Use grease gun, but not excess. Monthly Shell R2 Inspect once a week. Change oil of 600 hours of Omala oil HD220 Reducer Regularly using. Change it every year. Mobil Gear 630 ...
Page 87: Precautions
Section 9 TROUBLESHOOTING INTRODUCTION PRECAUTIONS GENERAL TROUBLES & SOLUTIONS MINOR TROUBLES & SOLUTIONS MOTOR TROUBLES & SOLUTIONS BLADE TROUBLES & SOLUTIONS SAWING TROUBLES & SOLUTIONS RE‐ADJUSTING THE ROLLER TABLE INTRODUCTION All the machines manufactured by COSEN pass a 72 hours continuously running test before shipping out and COSEN is responsible for the after sales service problems during the warranty period if the machines are used normally. However, there still exist the some unpredictable problems which may disable the machine from operating. Generally speaking, the system troubles in this machine model can be classified into three types, namely GENERAL TROUBLES, MOTOR TROUBLES and BLADE TROUBLES. Although you may have other troubles which can not be recognized in advance, such as malfunctions due to the limited life‐span of mechanical, electric or hydraulic parts of the machine. COSEN has accumulated enough experiences and technical data to handle all of the regular system troubles. Meanwhile, the engineering department of COSEN had been continuously improving the machines to prevent all possible troubles. It is hoped that you will give COSEN your maintenance experience and ideas so that both sides can achieve the best performance. 9‐1...
Page 88 PRECAUTIONS When an abnormality occurs in the machine during operation, you can do it yourself safely. If you have to stop machine motion immediately for parts exchanging, you should do so according to the following procedures:  Press HYDRAULIC MOTOR OFF button or EMERGENCY STOP button.  Open the electrical enclosure door.  Turn off breaker. BEFORE ANY ADJUSTMENT OR MAINTENANCE OF THE MACHINE, PLEASE MAKE SURE TO TURN OFF THE MACHINE AND DISCONNECT THE POWER SUPPLY. GENERAL TROUBLES AND SOLUTIONS DISCONNECT POWER CORD TO MOTOR BEFORE ATTEMPTING ANY REPAIR OR INSPECTION. TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Excessive belt tension Adjust belt tension so that belt does not slip on drive pulley while cutting ( 1/2“ Min. deflection of belt under moderate pressure.) Excessive head ...
Page 89: Minor Troubles & Solutions
MINOR TROUBLES & SOLUTIONS TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Saw blade motor does not run Overload relay activated Reset even though blade drive button Saw blade is not at forward Press SAW FRAME is pressed. limit position. FORWARD button MOTOR TROUBLES & SOLUTIONS TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Magnetic switch open, or Reset protector by pushing red button (inside protector open. electric box.) Motor will not start Low voltage Check power line for proper voltage. Open circuit in motor or loose Inspect all lead terminations on motor for loose connections. or open connections. Short circuit in line, cord or Inspect line, cord and plug for damaged plug. insulation and shorted wire. Motor will not start, Short circuit in motor or loose Inspect all lead terminations on motor for loose fuse or circuit connections ...
Page 90: Blade Troubles & Solutions
BLADE TROUBLES AND SOLUTIONS DISCONNECT POWER CORD TO MOTOR BEFORE ATTEMPTING ANY REPAIR OR INSPECTION. TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Too few teeth per inch Use finer tooth blade Loading of gullets Use coarse tooth blade or cutting lubricant. Teeth strippage Excessive feed Decrease feed Work not secured in vise Clamp material securely Teeth too coarse Use a finer tooth blade Misalignment of guides Adjust saw guides Dry cutting Use cutting lubricant Excessive speed Lower speed. See Operating Instructions “Speed Blade selection.” breakage Excessive speed Reduce feed pressure. Refer to Operating Instructions “Adjusting Feed.” Excessive tension Tension blade to prevent slippage on drive wheel while cutting. Wheels out of line Adjust wheels Guides out of line For a straight and true cut, realign guides, check bearings for wear. Excessive pressure Conservative pressure assures long blade life and clean ...
Page 91: Sawing Problems & Solutions
SAWING PROBLEMS AND SOLUTIONS Other than this manual, the manufacturer also provides some related technical documents listed as follows: Sawing Problems and Solutions Vibration during cutting Failure to cut Short life of saw blade Curved cutting Broken blade      Use of blade with incorrect pitch Use blade with correct pitch suited to workpiece width      Failure to break‐in saw blade Perform break‐in operation    Excessive saw blade speed Reduce speed   Insufficient saw blade speed Increase speed ...
Page 92: Re-Adjusting The Roller Table
RE‐ADJUSTING THE ROLLER TABLE If the feeding table suffers the huge stroke and the alignment is effected, follow the below procedure to adjust. TOOL, measuring Measurement, Horizontal balance Procedure 1. Screw or loosen the adjusting bolt to attain the horizontal balance (leveling) between the roller table and the machine frame. 2. Ensure that the machine frame is not struck by the loaded material on the feeding table. 3. Check the leveling by the measuring tool. 4. After finished the adjusting, fix the roller table. If the feeding table and the machine frame are not positioned under the horizontal balance, the loaded material may be going up gradually and affect the cutting effect. 9‐6...
Page 93: Section 10 - Parts
Section 10 PARTS SPARE PARTS RECOMMENDATIONS PART LIST SPARE PARTS RECOMMENDATIONS The following table lists the common spare parts we suggest you purchase in advance: Part Name Part Name Saw blade Coolant tank filter Wire brush Steel plates Carbide inserts Rollers Bearings Coolant pump Hydraulic tank leak‐proof asbestos Belt Rubber washer Duster seal Gear reducer Oil seal O‐ring Snap ring Drive wheel Idle wheel 10‐1...
Page 94 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 INDEX PART A MACHINE FOUNDATION ASSEMBLY …………………………………………………………………….10-4 PART B MAIN SHAFT & SUB SHAFT ASSEMBLY …………………………………………………………………10-6 PART B1 ENCODER ASSEMBLY …………………………………………………………………………………………….10-9 PART C BED ASSEMBLY …………………………………………………………………………………………………….10-10 PART D WORK FEED BED ASSEMBLY ……………………………………………………………………………….10-13 PART E FEED EQUIPMENT &...
Page 95 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART K WIRE BRUSH ASSEMBLY …………………………………………………………………………………….10-35 PART K1 BRUSH SHAFT ASSEMBLY ………………………………………………………………………………….10-37 PART L COVER ASSEMBLY ……………………………………………………………………………………………….10-38 PART M ELECTRIC BOX ASSEMBLY ……………………………………………………………………………………10-41 PART M1 REGULATOR SET ASSEMBLY ……………………………………………………………………………….10-42 PART M2 FLOW CONTROL VALVE ASSEMBLY …………………………………………………………………….10-43 PART N CHIP CONVEYOR ASSEMBLY (OPTIONAL) ………………………………………………………….10-44...
Page 96 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART A MACHINE FOUNDATION ASSEMBLY 10-4...
Page 97 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART A MACHINE FOUNDATION ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT C360L-1001 Base seat 底座 AHC-0153 adjusting bolt M20xP2.5xL80 底座調整螺桿 POA-20-25 M20xP2.5 螺母 AHR-1055 base support Ø80xD15...
Page 98 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART B MAIN SHAFT & SUB SHAFT ASSEMBLY 10-6...
Page 99 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART B MAIN SHAFT & SUB SHAFT ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT C360L-1101 main shaft 大主軸 POA-16-20 M16 xP2.0 螺帽 AHE-1094 bolt 下限定位支桿 PPA-16 washer 平面華司...
Page 100 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART B MAIN SHAFT & SUB SHAFT ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT C360L-1124 shaft 小軸限動桿 PBA-8-20 bolt M8xP1.25*20L 有頭內六角螺絲 C560L-1125 bracket 小軸限動座 C260L-1128 小軸軸承銷...
Page 101 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART B1 ENCODER ASSEMBLY PART NO : C360L-21000 PART NAME ITEM PART NO. PART NAME PART SPEC. COUNT UNIT (CH) C360L-2109 stop chain 定寸齒條 C360L-2121 Encoder plate 譯碼器調整板 AGB-70536 encoder bracket 譯碼器固定座(二)
Page 102 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART C BED ASSEMBLY 10-10...
Page 103 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART C BED ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT slide plate AHK-2801 固定床面鋼板 PBA-8-20 bolt M8 xP1.25x 20L 有頭內六角螺絲 front fixed vise jaw AHN-2809E 前固定虎鉗(二)
Page 104 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART C BED ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT bolt PBA-12-60 M12 x P1.75x60L 有頭內六角螺絲 plate AHK-2802A 鋸帶線鋼板 bolt PBA-6-20 M6 x P1.0x20L 有頭內六角螺絲 bolt PBA-8-30 M8 x P1.25x30L...
Page 105 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART D WORK FEED BED ASSEMBLY 10-13...
Page 106 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART D WORK FEED BED ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AHK-2911 feed vise bed 送料床身 AHK-2801 slide plate 固定床面鋼板 PBA-8-20 bolt M8 xP1.25x 20L 內六角螺絲...
Page 107 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART D WORK FEED BED ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT PPA-6 washer 平面華司 ∮6 PQA-6 spring washer 彈簧華司 ∮6 PBA-6-15 bolt M6 Xp1.0 x15L 有頭內六角螺絲...
Page 108 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART E FEED EQUIPMENT & FEED CYLINDER ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT C360L-23500-1 feed cylinder 送料油缸組 Ø60*405L PBA-12-45 bolt M12 x P1.75 x45L 有頭內六角螺絲...
Page 109 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART F WORK FEED ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AHB-1654A roller 滾輪 PP-14275 bearing 6205ZZ 軸承 AHA-1636 roller bracket 滾輪固定座 PBA-12-30 bolt M12 x 30L 有頭內六角螺絲...
Page 110 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART G IDLE WHEEL MOTOR ASSEMBLY 10-18...
Page 111 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART G IDLE WHEEL MOTOR ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT C360L-3001 housing yoke 鋸弓 C360L-30300 idle wheel 上輪組 AHA-06029 tension ass'y 張力滑座滑板組 AHA-0403 lock washer 鎖緊墊圈...
Page 112 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART G IDLE WHEEL MOTOR ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT 79 AGC-1033 bracket 中限開關座 81 PPA-5 washer 平面華司 83 PQA-5 spring washer 彈簧華司 85 PBA-5-12...
Page 113 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART G1 IDLE WHEEL ASSEMBLY PART NO : C360L-30300 ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AHR-2007 idle wheel 上輪 AHA-0635 wheel shaft 上輪軸 PP-14613 30207 滾錐軸承...
Page 114 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART G2 TENSION ASSEMBLY PART NO : AHA-06029 ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AHA-0612A tension body 張力滑座 AHA-0608A slide piece 張力滑板 AHA-0603 guide plate 壓板...
Page 115 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART G3 TENSION CYLINDER ASSEMBLY PART NO : AHA-06189-1 ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT cylinder rear cap AHA-0618C 張力油缸後蓋 o-ring P-11 PP-59050 O 型環 needle rod AHB-0651 切換閥針...
Page 116 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART G4 GEAR BOX ASSEMBLY PART NO AGC-03040 ： 10-24...
Page 117 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART G4 GEAR BOX ASSEMBLY PART NO AGC-03040 ： ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AGC-3008 hinge bracket 減速機本體 AHA-0305 worm 蝸桿 PS-4-7 4 x 7 x 50L 方鍵...
Page 118 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART H DRIVE WHEEL MOTOR ASSEMBLY 10-26...
Page 119 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART H DRIVE WHEEL MOTOR ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AHA-0514G reducer pulley 減速機皮帶輪 MAE-2025 washer 上輪軸墊圈 ACA-1074 washer 蝸輪軸墊圈 C360L-3377 shaft 蝸桿接軸 AHA-0525 washer 墊圈...
Page 120 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART J GUIDE BRACKET ASSEMBLY 10-28...
Page 121 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART J GUIDE BRACKET ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT C260L-3102 plate 滑板調整板 PBA-10-20 bolt M10 x 20L 有頭內六角螺絲 PAA-10-15 set screw M10 x 15L 止付螺絲...
Page 122 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART J GUIDE BRACKET ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AHG-0938 block 急降桿配重 PBA-6-50 bolt M6 x 50L 有頭內六角螺絲 POA-6 螺帽 PLA-6-40 hexagon head bolt M6x40L 外六角螺絲...
Page 123 & 6(5,(6 3$57 /,67 3$57- /()7 ,16(57 +2/'(5 $66(0%/< 10-31...
Page 124 & 6(5,(6 3$57 /,67 3$57- /()7 ,16(57 +2/'(5 $66(0%/< 10-32...
Page 125 & 6(5,(6 3$57 /,67 3$57- 5,*+7 ,16(57 +2/'(5 $66(0%/< 10-33...
Page 126 & 6(5,(6 3$57 /,67 3$57- 5,*+7 ,16(57 +2/'(5 $66(0%/< 10-34...
Page 127 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART K WIRE BRUSH ASSEMBLY 10-35...
Page 128 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART K WIRE BRUSH ASSEMBLY PART NO : C360L-32200 ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AGC-3025 brush cover 鋼刷護蓋 AGC-3027 brush bracket 鋼刷護蓋固定板 PPA-8 washer 平面華司...
Page 129 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART K1 BRUSH SHAFT ASSEMBLY PART NO : AHA-12110 ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AHA-1211 bearing bracket 軸承座 PBA-8-40 bolt M8 x 40L 有頭六角螺絲 PPA-8 washer 平面華司...
Page 130 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART L COVER ASSEMBLY PART NO C360L-14000 ： 10-38...
Page 131 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART L COVER ASSEMBLY PART NO C360L-14000 ： ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT C360L-1401 Left cover 左底盤 PPA-6 washer 平面華司 PQA-6 spring washer 彈簧華司 PBA-6-10...
Page 132 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART L C0VER ASSEMBLY PART NO C360L-14000 ： ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT PQA-6 spring washer 彈簧華司 101 PBA-6-10 bolt M6 x 10L 有頭六角螺絲 103 C260L-1445A Right fence 右後支撐架...
Page 133 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART M ELECTRIC BOX ASSEMBLY ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT C560L-1321 elec.data plate 控制面板 C560L-1323 control plate 面板底板 AHC-0134A-CE elec.data plate DIN CS-198 流量閥控制面板 PFA-8-8...
Page 134 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART M1 REGULATOR SET ASSEMBLY PART NO : AHA-10289 ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT PBA-5-45 bolt M5x45L 有頭內六角螺絲 AHA-1036 rear cap 後蓋 AHA-1030 valve 針閥...
Page 135 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART M2 FLOW CONTROL VALVE ASSEMBLY PART NO : AHA-6100 ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AHA-1039 valve seat 閥座 AHA-1043 valve sleeve 針閥套筒 PP-59071 o-ring P-15 O 形環...
Page 136 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART N CHIP CONVEYOR ASSEMBLY (OPTIONAL) PART NO C360L-C001 ： 10-44...
Page 137 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART N CHIP CONVEYOR ASSEMBLY (OPTIONAL) PART NO C360L-C001 ： ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT C360L-4001 basket 切屑槽 AGF-1027 leader screw 除屑螺旋 AHN-1416A 除屑螺桿 AHN-1411 bearing bracket 軸座...
Page 138 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART O ANTI-VIBRATION ROLLER ASSEMBLY (OPTIONAL) PART NO AHA-33010 ： 10-46...
Page 139 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART O ANTI-VIBRATION ROLLER ASSEMBLY (OPTIONAL) PART NO AHA-33010 ： ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AHA-3303 roller housing 防震座 AHA-3305 anti-vibration roller shaft 固定導輪軸 PPA-16 flat washer 平面華司(公)
Page 140 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART P VISE HYDRAULIC PRESSURE REGULATOR (OPTIONAL) PART NO: AHA-10400 ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT PP-43127A relief valve 減壓閥 RSW-902 PP-43311 pressure gauge 壓力表 70kg* 2 1/2 * 1/4PT...
Page 141 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART Q CHECK STRAIGHT SENSOR MODULE (OPTIONAL) PART NO: AHC-33010 O P T IO N A L A S S E M B L Y ITEM PART NO. PART NAME PART NAME (CH) PART SPEC.
Page 142 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART R OIL FILTER ASSEMBLY PART NO : AGB-707270 ITEM PART NO. PART NAME PART NAME (CH) PART SPEC. COUNT UNIT AGB-70727 filter frame 濾油器本體 AGB-70730 filter 濾油器芯 AGB-70729 spring 濾油器彈簧 AGB-70728 濾油器蓋...
Page 143 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART S HYDRAULIC ASSEMBLY INSTRUCTION 10-51...
Page 144 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART S HYDRAULIC ASSEMBLY INSTRUCTION 10-52...
Page 145 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART S HYDRAULIC ASSEMBLY INSTRUCTION 10-53...
Page 146 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART S HYDRAULIC ASSEMBLY INSTRUCTION ITEM PART NO. PART NAME PART SPEC. COUNT UNIT PART NAME (CH) PP-31421 Hydraulic motor 液壓馬達 PP-322220 Hydraulic pump VCMSF20B10 液壓泵浦 SJM-4043-1 Plate 油路板 SJM-4043-1 Plate 油路板...
Page 147 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART S HYDRAULIC ASSEMBLY INSTRUCTION ITEM PART NO. PART NAME PART SPEC. COUNT UNIT PART NAME(CH) 101 PUJ-030-020-03 Elbow 90° 3/8Px1/4H 彎頭 103 PUI-030-020-01 Joint 3/8Px1/4H 接頭 105 PUJ-030-020-03 Elbow 90° 3/8Px1/4H 彎頭...
Page 148 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART S HYDRAULIC ASSEMBLY INSTRUCTION ITEM PART NO. PART NAME PART SPEC. COUNT UNIT PART NAME (CH) 201 PUK-030-030-020-01 Elbow 3way 3/8Px3/8Hx1/4H 三通彎頭 203 PUI-030-020-01 Joint 3/8Px1/4H 接頭 PUI-030-030-01 Joint 3/8Px3/8E 接頭...
Page 149 PART LIST C3 （ C-360LNC-99 ） series S1-20091118 PART S HYDRAULIC ASSEMBLY INSTRUCTION From PART NO. PART NAME PART SPEC. COUNT UNIT PART NAME (CH) 65 ->oil tank PRESSURE PIPE 3/4x3/4x600L 壓力管 117 -> oil tank PP-80051D RETURN PIPE 1/4x1100L 回油管...
Page 150 Section 11 Warranty Warranty New machines are warranted to be free from defects in workmanship and material for a period of one (1) year from the date of shipment by Seller. The warranty period is based on normal usage of two thousand eighty hours (2080) per year and is reduced proportionately for any excess usage. Products, which under normal operating conditions in Buyer’s plant are defective in workmanship or material, will be repaired or replaced at the option of Seller. This warranty does not cover shipping freight charges for either the return of the defective part or for the shipping of the replacement or repaired part. Seller will have no obligation to repair or replace perishable parts, or materials or parts damaged by misuse, negligence or failure of Buyer to provide appropriate maintenance and service as stated in the operator’s manual or industry standard and normally acceptable practices. This warranty does not apply if the machine has been altered or modified without our prior written consent. In the case of components or units purchased by Seller including work holding devices, tool holders, motors and controls, the warranty shall not exceed that received by Seller from the supplier of such components or units. Seller will not assume responsibility for products or components returned to Seller without prior consent or for unauthorized repairs to its products, even though defective. Electrical Equipment: The warranty available for all electrical components to the Buyer will be voided if the voltage supplied to the machine is found to be outside the stated voltage of the machine by +/‐ 10% and/or grounded at machine. Accessories Supplied with Manufacturer’s Equipment: The warranties available to the Buyer are those extended by the accessory manufacturer, if any, to the extent they are in force and effect. The ACCESSORY MANUFACTURER’S WARRANTY, if any, is exclusive and is in lieu of all other warranties whether written, oral or implied. 11‐1 ...
Page 151 COSEN SAWS Vertical Plate Saws Horizontal Billet Saws NC/CNC Band Saws Structural Miter‐Cutting Saws Automatic Band Saws Visit our website at www.cosen.com COSEN MECHATRONICS CO., LTD. ...

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