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Kalamazoo AH9AW Operating And Maintenance Manual

Metal cutting saws
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Oper�ting and Maintenance Manual
•
This operating manual should be read by everyone expected to operate
or supervise the operation of this machine. Special attention should be
•
KALAMAZOO®
Metal Cutting Saws
focused on the pages concerning safety.
For your convenience when ordering parts, please fill in the following
information when you receive your new Kalamazoo saw.
Model _____ _
Serial No. ______ _
For Parts and Service, call:
Kalamazoo is committed to continuous product improvement. In
keeping with this commitment, we reserve the right to change the
information in this manual without notice. Every attempt has been made
to insure the accuracy of this manual. Even so, Kalamazoo assumes
m;, responsibility for errors or omissions, nor is any liability assumed
for damages resulting from the use of the information contained in
I Kalamazoo Saw: A Division of Clausing Industrial
'
I
I
Model AH9AW 'Kalamatic'
S/N AH1015 and above
Manual P/N KAL-07
Revised January, 1995
(800) 575-2843
this manual
Kalamazoo, Ml 49007

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Summary of Contents for Kalamazoo AH9AW

  • Page 1 Every attempt has been made • to insure the accuracy of this manual. Even so, Kalamazoo assumes m;, responsibility for errors or omissions, nor is any liability assumed for damages resulting from the use of the information contained in...
  • Page 2 • Model AH9AW Table of Contents Section 1: General Information Safety Instructions..............1.1-1.3 Specifications and Dimensions ..........1.4-1.5 Warranty ................:..1.6 Section 2: Installation Saw Installation ..............

  • Page 3: Table Of Contents

    • ModelAH9AW Table of Contents (continued) Section 7: Electrical Switch Panel Assembly ..........•..•..7 .1 Electrical Enclosure Parts ............7 .2 Head Up/ D own Limit Switch Parts ........... 7 .3 Changing Operating Voltage ...
  • Page 4 • Safety Instructions Kalamazoo bandsaws are designed and built according to the American National Standards Institute (ANSI) specifications· for metal-cutting bandsaws (see ANSI B11.10-1990). Each machine is equipped with fixed and movable guards to protect personnel from moving parts wherever possible. Due to the general purpose nature of these machines, it is impossible for Clausing Industrial Inc.
  • Page 5 • Safety Instructions ( continued) 7. Always remember that this machine has hydraulic head frame movement. Keep away when it is moving. 8. Always support long material on both sides of the work area to prevent the material from falling to the floor.
  • Page 6 • Safety Instructions · ( continued) lock the disconnect switch in the 'Off' position when the saw is not in use to prevent Always unauthorized use. 23. Report any unus. u al or questionable sounds, conditions, or machine actions to the proper person . 24.
  • Page 7 Saw Specifications ModelAH9AW 9" Cutting Capacity @ 90· (Round) (Rectangle) 9" X 12" Vise Opening 16" Cutting Speeds (infinitely Variable) 62-390 sfpm 10' 10 1/2" Blade Length (1" wide x .035") Blade Wheel Diameter 14" Height to Working Surface 25 1/2" 1170 Shipping Weight (pounds) Construction Specifications...
  • Page 8 •· Floor Space Requirements • Height Height <Head Down) ( H ead Up) 6 3 " 3 81/2 " 6 9" 88 " •...
  • Page 9 Warranty Each Kalamazoo saw is warranted to be free of defects in materials and/or workmanship for a period of two years from the date of installation. This warranty is limited to facto ry defects and specifically excludes items subject to normal wear (see lists below). Moreover, this warranty only applies to machines...
  • Page 10 • Saw Installation ModelAH9AW 1-:. � "II Your saw has been shi peel on two separate skids. After removing the plastic wrapping around the saw, check to see that all items are present and that no damage exists. Remove the lag bolts t�at hold the saw on the shipping skid. Lift the saw off the skid using either a fork-type lift or a chain/sling arrangement.
  • Page 11 Electrical Connection Your machine is wired to operate on the voltage shown on the tag wired to the electrical enclosure. It is • very important to check that your supply voltage to the saw matches the voltage on the tag before energizing the saw.
  • Page 12 - � • Hydraulic Connection There are three hydraulic lines to connect from the barfeed to the saw. Hose #1 comes from the head lift cylinder and connects to the flow control valves found on the right side of the barfeed near the console. Hoses #2 and #3 come from the vise cylinder and connect to the valve manifold at the front of the barfeed unit.
  • Page 13 • Operator Controls AH9AW - ., _ o�o BERGENCYi Ill.ADE POWER COUNTER - ,o ,_,: ,o VISE COOU."'1' STaP ® - CUIIP � � � neno FEED Pl.ltP RCU. - ® PECE CDIMTER. • 1. Emergency Stop/Pump Start: Twisting the red mushroom head button (clockwise) will start the hydraulic pump motor and energize the saw's electrical system.
  • Page 14 • Operator Controls AH9AW ( continued) 8. Programmable Counter: To Program: Press and hold the 'I' key (see below). The current preset value will be displayed and the 'I' indicator will flash in the upper left comer of the display To change any number in the preset press the button under that number.
  • Page 15 • Operator Controls AH9AW KNllUO 'HE AD UP' AD JUSTMENT NUTS ( continued) Travel Adjustment The head travel can be adjusted Head Knobs: using the threaded stop and limit switches on the rod to the left of the fixed vise jaw;(as viewed from the rear of the saw). Raising the top knob allows the head to raise higher, while raising the lower knob will cause the head to stop at a higher point.
  • Page 16 • Blade Speed Adjustment BLADE SPEED ADJUSTMENT KNOB • • • Turning the blade speed knob counter-clockwise will increase the blade speed; clockwise will decrease blade speed. Do not adjust the blade speed unless the saw is running! Blade Speeds (S.F.P.M.) (approximate) Blade Dial...
  • Page 17 • Feed Pressure Adjustment Springs ModelAH9AW The springs control ttje cutting pressure of the saw. The feed pressure (or 'head weight') should be increased when cutting 'difficult' materials and decreased for easy-to-cut materials. The head weight is increased by shortening the springs and decreased by lengthening them. ADJSTMENT KNOB •...
  • Page 18 • Operating Procedure AH9AW VISE KNOB 1. Before starting production, always check the following: area and machine should be clean and free from trip hazards. There should be no a) The work • chips, scrap pieces, or tools laying on the saw. Be sure the floor is not slippery .
  • Page 19 • Manual Cutting (continued} 6. Push the green section of the 'Blade' switch to start the blade motor. Tum the 'Coolant' switch to 'On' and adjust the flow with the valves at the top of each guide block. When ready to cut, tum the 'Vise' switch to 'Clamp/Feed' to feed the head into the workpiece.
  • Page 20 • Automatic Cutting continued) 6. If desired, the counter can be set for a preset number of cuts (see page 3.2). Note: the automatic cycle will not operate with the 'Counter' switch 'On' and the counter reading 'O'. 7. Raise the head until the 'Head Up' limit switch is in contact with the knurled stop nuts. Start the blade motor and the coolant pump.
  • Page 21 • General Cutting Tips Horizontal Saws When starting with a new blade, always check the blade tension after a few cuts. Tighten as necessary. Use a cutting solution (coolant) whenever possible (except on cast iron, bearing bronze, or die tool steel). This helps reduce heat:buildup while lubricating the blade.
  • Page 22 • Blade Selection and Sawing Controls ModelAH9AW Blade Selection: Raker set blades are recommended. The workpiece thickness determines the number of teeth per inch required. Never less than 2-3 teeth should be in contact with the workpiece at any time if possible, and no more than 7 teeth.
  • Page 24 • Recommended Cutting Speeds Surface Feet per Minute (S.F.P.M.} Aluminum ........150-340 Brass .......... 80-200 Bronze ........
  • Page 25 Regular Maintenance ModelAH9AW * Disconnect and lo�out power to the saw before performing maintenance on this saw! • * Gearbox Lubricati�n: Check the oil level after the first 24, 100, and 500 hours of operation. To check the oil level, remove the oil plug (see illustration). It may be necessary to rotate the drive wheel to gain access to the plug.
  • Page 26 • Coolant Pump Maintenance Caution: Disconnect and lockout the power before attempting any maintenance on the sawl 1. This unit is self lubricating. Oiling is not required. Do not open the sealed portion of the unit or remove housing screws. 2.
  • Page 27 • Blade Speed Handwheel Adjustment When the blade s� hand wheel is turned fully clockwise, the pulleys are at their slowest speed. At this point, the needle on the dial should point to '1'. If it does not, it should be adjusted as follows: 1.
  • Page 28 • Spare Parts List ModelAH9AW Blade Brush ............. 9A-271 Drive Belt ..............13A-2050 Power Fuses (1-3FU): 208/230V Saws Bussman Type KTK-R-15 Gould Type ATMR-15 Littlefuse Type KLK-R-15 460/575V Saws Bussman Type KTK-R-9 Gould Type ATMR-9 Littlefuse Type KLK-R-9 Control Circuit Fuses (4FU - on transformer) Bussman Type FNM 2 1/2...
  • Page 29 • Blade Tracking Blade Tracking is the 'Wheel Alignme nt ' of your saw. Every time th e blade is changed you should check the tracking as showr:i below: IDLER WHEEL DRIVE WHEEL · CHECK TRACKING AT ARROWS F"IG. I •...
  • Page 30 • Drive Wheel Tracking Adjustment Note: Disconnect and lockout the power to the saw before making adjustments! 1. Note which condition (excessive or negative cant) must be corrected. 2. Unscrew the blade tension handle to remove the tension from the blade. 3.
  • Page 31 • Idle Wheel Tracking Adjustment Note: Disconnect and lockout the power to the saw before making adjustments! 1. Note which condition (excessive or negative cant) must be corrected. 2. Unscrew the blade tension handle to remove the tension from the blade. 3.
  • Page 32 • Blade Guide Adjustment Disconnect and lock out power to the saw before adjusting the blade guides! Prior to installing or adjusting the blade guide block assembly, the blade must be in place, properly tensioned, and tracking correctly on the bandwheels. Once the blade guide block assembly is bolted to the guide arm, there are two adjustments that can be made: 1.
  • Page 33 • V-Belt Troubleshooting Guide Problem Possible Cause Recommended Solution 1. Rapid V-Belt Wear a) Rubbing belt guard a) Check guard clearance b)Wom pulley b) Check pulley side walls - replace as necessary c) V-Belt slipping c) Increase tension d) Improper belt installation, belts d) Replace belts, do not pry pried over pulley belts over pulley...
  • Page 34 Variable Speed Pulleys Helpful Hints and Safety Helpful Hints: 1. Check alignment of the drive at other than 'set-up' speed.· Misalignment will cause the belt to overheat and wear rapidly. 2. Observe pulley runout. A good rule of thumb is .001" per inch of pullE:ly diameter is acceptable. 3.
  • Page 35 • Troubleshooting Guide • 1. Motor WIii not start a) Check overload relay; reset if necessary. b) Check wiring for proper voltage; refer to the red tag on the electrical enclosure for the voltage the saw is wired for. c) Check the starter coll; replace as necessary. d) Check wiring for open circuits in the plug, cord, or incoming line;...
  • Page 36 Troubleshooting Guide (continued) 7. Blades are stripping teeth • a) Too many teeth per inch will cause overloading of each tooth; too coarse a blade will allow the teeth to 'crash' into the workpiece; Try to have at least 3 teeth in contact with the work at all times.
  • Page 37 • Troubleshooting Guide ( continued) 14. Blade 'chatters' during the cut a) Try reducing the blade speed. b) Review the blade selection; see page 5.4. c) Check to see that the drive pulleys and/or band wheels are tight; repair or replace as necessary.
  • Page 38 Operator Controls • AH9AW IIIIUIIB FEED R0U. PEtE CIUITER • Item Part No. Description Qty. CS-5022-1 Red Mushroom Head Switch Operator 1 CS-5063-1 White Pilot Light Lens CS-5025-1 Light Module CS-5027-1 N.C. Contact Block CS-5028-1 N.O. Contact Block CS-5029-1 Blade On/Off / Pump On/Off Switch...

  • Page 39: Electrical Enclosure Parts

    Electrical Enclosure Parts • AH9AW VIEW A-A • ♦ Descri12tion Part No. Item Qty. CS-5020A-1 Contactor (208/230V) 9A-5030-1 Motor Contactor (460/575V) 208/230/460V 250VA Transformer CS-5019 CS-5020B2-1 Overload Relay: 230V/1 ph 9A-5031D-1 Overload Relay: 208-230V/3 ph 9A-5031C-1 Overload Relay: 460/575V/3 ph...

  • Page 40: Head Up/Down Limit Switch Parts

    Head Up/Down Limit Switch Parts • • ♦ ♦ Part No. Item Description Qty. 9A-4612 Stop Collar AB-17119 Limit Sw.: Micro Switch #BZE6-2RO62 1 AB-17122 Limit Sw.: Omron #ZE-NA2-2S AB-18111-2 Frame Cylinder Mounting Trunion AB-18113-1 Rod Connector Bolt AB-18115 Adjusting Knob AB-18116-1 Stop Rod AB-18118-2...

  • Page 41: Changing Operating Voltage

    Changing Operating Voltage • AH9AW If it should become necessary to change the operating voltage of your Kalamazoo saw, it can be done as follows: 1. Disconnect and lock out the electrical supply to the sawl 2. Power Fuses: Whenever voltages are changed, the power fuses may need to be changed.
  • Page 42 Changing Operating Voltage • AH9AW ( continued) Depending on the operating voltage, the following overload relays are used: Overload Relay: Single Phase Three Phase 230V 208/230 460/575 Motor Contactor (1-2M) CS-5020A-1 CS-5020A-1 9A-5030-1 Motor Overload Relay (1-2MOL) CS-502082-1 9A-5031 D-1...
  • Page 43 Changing Operating Voltage AH9AW ( continued) 5. Replacing the blade motor: To change the blade motor, disconnect and lockout power to • Loosen the top nut on the motor tensioning rod far enough to remove the drive the sawl belt. Loosen the set screws that clamp the speed adjust knob and the drive pulley to the motor shaft and remove the knob and pulley.
  • Page 44 <r � "j -· , Changing the Parts Counter • ModelAH9AW COUNTER SWITCH NUMBERS WIRE SPRING MOLDED INTO COUNTER CASE (REF. STEPS <REF. STEP 41 3 ANO Sl 911tl1291'1516 POWER SWITCH ENCLOSURE PANEL TERMINAL STRIPS 1. Loosen the screws to open the counter enclosure. 2.

  • Page 45: Parts Counter Wiring

    Parts Counter Wiring • AH9AW WHITE/RED YELLOW RED--­ CNOT PART OF MUL Tl-CONDUCTOR CABLE) WHITE • 120VACn40VAC POWER SWITCH SWITCH SETTINGS ON SIDE OF COUNTER SWITCHES 1, 2. 9. 10, 11 SHOULD BE 'ON' ALL OTHER SWITCHES SHOULD BE 'OFF' POWER SWITCH SHOULD BE SET FOR 120V •...
  • Page 46 • • • NOTE: INCOMING POWER LEADS TO NOTE: USER TO SUPPLY ANO INST ALL FUSED SAFETY SWITCH. SWITCH SHOULD BE AWG 10 MINIMUM - 112• CONDUIT BE INST ALLEO PER THE NATIONAL r --------- !TRADE SIZE> ELECTRIC CODE 1DISC 1F�...
  • Page 47 • • • NOTE: INCOMING POWER EADS TO NOTE: USER TO SUPPLY AND INST ALL FUSED SAFETY SWITCH. SWITCH SHOULD BE AWG 10 MINIMUM - 112• CONDUIT BE INSTALLED PER THE NATIONAL (TRADE SIZE> ELECTRIC CODE 1DISC ,--------- I 1F� : 1MOL L1 1 ..JJ1 ----- ----------'...
  • Page 48 Hydraulic Tank Assembly • • Item Part No. Descrigtlon Qtv. AB-1031-2 Hydraulic Tank Weld. m ent AB-10318-1 Tank Filler Tube AB-10323 Tank Opening Gasket AB-10324 Filter Opening Gasket AB-10411-1 Pump/Motor Plate AB-10413-2 Pump/Motor Coupling AB-10414-1 Hydraulic Pump AB-4013 3 Station Manifold AB-4011 Single Solenoid Directional Valve AB-14142-1...
  • Page 49 Head Feed Cylinder (AB-1411) • Feed Roll Cylinder (AB-1411-1) u:> 1/a-Z'l NPT • Item Part No. Descri�tion Qty. AB-13313-1 Upper Cylinder Head V20-7150 Bushing: Bunting P50-4 X-118 Oil Seal: National #41442S AB-13324-1A U-Cup Seal: Sheffer #150-0150-0118 AB-13324-1 B Backup Ring: Shamban #S46091 AB-13325 Piston AB-14111...

  • Page 50: Head Speed Parts

    Head Speed Parts • HEAD RAISE SPEED VAL VE PIPE SEALANT TO BE USED AT BOTH ENOS OF PIPE NIPPLE HEAD LOWER SPEED VAL VE Item DescriQtion Part No. Q tv . • Control Valve Bracket AB-10216 1/8NPT Flow Control Valve H-12204 1/4-20UNC x 1/4 Socket Set Screw 1/8NPT x 3"...

  • Page 51: Hydraulic Maintenance

    Hydraulic System Maintenance • Your saw was shipped with 7 gallons of hydraulic oil in the tank. For the best operation of your saw, the oil should be maintained as follows: Oil Change Schedule (normal to moderately heavy use) Mobil 'DTE-24' hydraulic oil: replace every three years. Other hydraulic oils: replace every two years.

  • Page 52: Hydraulic Schematic

    • > Hydraulic Schematic • ® AH9AW -'SOL © 2S0L FEED VISE R0U. a.NP DOWN 1S0L FEED ROLLER ,- -- -- -----7 SSOL 3S0L ® FEED HEAD RAISE ® ® t� ®) G.At1P SET I VISE 400 PSI 2 1/2 BORE 2 HP ®...
  • Page 53 Blade Brush Assembly • (Part No. 9A-27) Part No. Description Item Qty. 9A-270 Blade Brush Bracket 9A-271 Blade Brush 9A-272 Brush Axle Spacer • 9A-273 1/2 x 5/8 Socket Shoulder Bolt C6A-1915 Tightener Knob (not part of 9A-27) 3/8-16UNC Hex Nut 3/8 Internal Lock Washer Blade Guard Parts f - -- -�...
  • Page 54 Guide A rm Asse m b l y (Roller Gui de s) • Assembly No. 9A-1974 NOTE: 9A-1930 BLADE GUARD BRACKET IS TO • BE USED ON LEFT HANO GUIDE ARH ONLY Description Item Part No. Qty. 9A-1974 Complete Guide Arm Assembly 9A-190 Guide Arm for H9AW SC-1915...

  • Page 55: Carbide Guide Assembly

    : , , : t Carbide Guide Assembly • Assembly No. 9A1901C (Left Hand) Assembly No. 9A1902C (Right Hand) NOTE: 9A-1930-C NOT SHOWN IN THIS VIEW • �- Item Part No. OescriQtion 9A-192-1C Carbide Guide Block 9A-195 Carbide Insert 9A-194 L.H.
  • Page 56 ·e1ade Tension Assembly • • Description Item Part No. Qty. Rocker Block Slide Block S-34 Slide Block Guide S-23 Blade Tension Screw SC-124 Tension Screw and Frame Bracket Blade Tension Handle S-13 S-23-1 Washer 9A-2211-1 Frame Rest Assembly (includes items 10-12) •...

  • Page 57: Coolant Parts

    Co ola nt Part s • • �- Item Part No. Descriotion 9AW-3 Coolant Pan C-855 Coolant Hose C-37 Drain Nipple C-49 Barbed Hose Fitting SCW-13 Coolant Tray/Pan Support Bracket 9AW-43-1 Coolant Pump • C-16 Chip Tray C-14-1 Mounting Bracket. H9AWSA C-12 Flow Control Valve H3-3005...
  • Page 58 Head Weight Compensation Spring Parts • AH9AW 3/8" HFN 3/8" ITW }--..._,"""\,,@.� 9A·175 9A-172 / S-23-1. __ ,,,� . ,,,. · _r3/8" HFN < . '-...___ l> ,,,,- · , '--.'---, � _,/· __,)<. K-145-1 "-.._ ,______,_. 9 A• 17 4 •...

  • Page 59: Support Arm Parts

    Support Arm Parts • • Qty. Item Description Part No. SC-123-1 Pivot Bar 9A-121 Long Arm SC-12167 Adjusting Collar SC-122 Short Arm •...
  • Page 60 Motor Mo unt and Tension Compon ents • • 6�----tl Item Part No. Descri12tion Qtv. 9A-180 Motor Mounting Hinge L-33A Motor Plate 8C-182 Motor Plate Pivot Bar L-72 3/8 (#SA) Hairpin Cotter 13A-8250 Stud 8C-183 Tension Rod •...
  • Page 61 Variable Speed Drive Parts • · ' • (CH ART ONL Y) Item Part No. Descri12tion Qtv. S-11 3 Key: 3/16" Sq. x 1 1/2" long SC-2040-1 Pulley Guard 9A-2041A Drive Pulley: 7/8" Bore (on motor) 9A-2042 Driven Pulley: H9AWSA •...
  • Page 62 Bed a nd Leg Parts • : tr . • ·Item Part No. Description Qty. 9A-100-1 Saw Bed 9A-101 Front Leg 9A-102 Rear Leg H-16506 Grease Fitting AB-19111 Tipoff Block AB-10217 Tipoff Chute • 9. 10...
  • Page 63 Head Frame Parts and Wheels • ,.(j) • �- Item Part No. Descrimion X-132-1 Lock Nut SA-141-1 Lock Washer S-25-1 Idle Wheel Jam Nut X-7A-2 Drive Wheel X-78-2 Idle Wheel 9A-120 Head Frame: H9AWSA SC-1212 Guide Arm Support Yoke X-500 Gearbox Assembly: H9AWSA •...

  • Page 65: Idle Wheel Assembly

    Idle Wheel Assembly • � � S- 101 • Item Part No. Descri�tion Qtv. S-25 Idle Wheel Axle X-141 Idle Wheel Spacer X-158 Idle Wheel Snap Ring S-101 Idle Wheel Bearing S-25-1 Idle Wheel Jam Nut X-7B-2 Idle Wheel: H9AWSA •...

  • Page 66: Gearbox

    Gearbox Assembly • • 9.14...
  • Page 67 Gearbox Assembly • �- Item Part No. Descri12tion Gearbox Casting Bronze Gear X-19H Barrel Cover S-36 Back Plate X-36 Small Oil Seal Casting X-56 Large Oil Seal Casting X-115 Back Cover X-116 Back Plate Gasket X-117 Large Oil Seal: National #410163 X-122 Small Oil Seal: National #471554 X-123...

  • Page 68: Frame Cover Parts

    Frame Cover Parts • -<..: ___ _ ---, t-4 • �- Item Part No. Descrigtion H-15301 Kalamazoo Logo S-96B Tinnerman Nut S-96 Stem Bumper SC-211 Serial and Lube Plate SC-210 Cover • 9.16...

  • Page 69: Feed Roller Parts

    Feed Roller Parts • �- • Item Part No. Descri12tion AB-1311-1 Feed Roller Frame AB-13118 Feed Roller Frame Axle Retaining Ring: Truarc #5133-50 AB-1321 Knurled Feed Roller AB�1321C Coated Feed Roller (optional) AB-1345 Feed Roller Pillow Block AB-1347 Feed Roller Hydraulic Motor AB-13481 Motor Mounting Bracket AB-13482...

  • Page 70: Barfeed Base Parts

    Barfeed Base Parts • • Item Part No. Descr112tion Qty. AB-1011-1 Base Frame AB-10120 1/2-13UNC x 3 Elevator Bolt AB-10211 Top Cover AB-10212 R.H. Side Cover AB-10213-5 L.H. Side Cover AB-10214 Back Panel AB-11111 R.H. Table Side Rail AB-11112 L.H. Table Side Rail AB-1114 Table Rail Spreader AB-1121...

  • Page 71: Feed Length Control Parts

    Feed Length Control Parts • • Item Part No. Descriotion Qty. AB-19501 Switch Mounting Arm Actuator Plate and Pin AB-19511-1 AB-19531 Lock Handle AB-19521-1 Stock Stop Screw AB-19522-1 Adjusting Wheel AB-19512-2 Indicator Plate #8-32UNC x 1/4 Round Head Screw Limit Switch AB-17118 Lock Screw Weldment AB-1921...

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