USE AND MAINTENANCE MANUAL WILLY 225 YEAR OF MANUFACTURE:

Transcription

1 USE AND MAINTENANCE MANUAL EN WILLY 225 YEAR OF MANUFACTURE:

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3 MEP Conformiy Declaraion EN CE CONFORMITY DECLARATION (according o machine direcive 9/37/CE annex II A) The manufacurer: SPA SEGATRICI Via Papa Giovanni XXIII, Pergola (PS) ITALIA Tel. 0721/ Fax 0721/ hereby declare ha he accessory for bandsawing machines and circular sawing machines for meals: Machine model: SMV Serial number: Year of manufacure: is in specificaion wih he following direcives: D DIRECTIVE 9/37/CE MACHINE DIRECTIVE D DIRECTIVE 73/23 LVD D DIRECTIVE 9/33 EMC D DPR 459/9 Presidene (EZIO MAGNANI) Pergola

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5 INDHOLDSFORTEGNELSE SIDE Operaion and mainenance manual for WILLY FOREWORD... 1 TECHNICAL DATA TABLE... 1 INTRODUCTION... 2 MACHINE SPECIFICATIONS... 2 CHAPTER Funcional pars of he machine Cuing head Vice Lubrican/coolan sysem... 4 CHAPTER Safey Inended use of he machine General recommendaions Recommendaions for he operaor Machine safey devices Reference sandards Proecion agains accidenal conac wih he blade Elecrical equipmen Airborne noise from he machine Mehods of measuring sound level values Noise level values... 7 CHAPTER Insalling he machine Unpacking he machine Check lis Minimum requiremens Moving he machine Connecing elecrical power supply... 9 CHAPTER Machine operaion Descripion of conrols Manual operaing cycle CHAPTER Drawings, exploded diagrams and spare pars Diagrams Elecrical diagrams Exploded diagrams Head uni Vice uni CHAPTER --- Adjusmens Blade Performing angled cus Changing blade... 1 CHAPTER Mainenance and choice of expendable maerials Role of he operaor responsible for he machine Recommendaions for mainenance General machine mainenance Daily Willy 225

6 Weekly Monhly Mainenance of working unis Transmission box Expendable maerials Transmission box oils Oils for he lubrican/coolan fluid CHAPTER --- Choice of blades Choice of blade Tooh pich Cuing and feeding speed Lubricaing/cooling fluid Blade srucure Types of blade Recommended cuing parameer able Classificaion of seels Seel nomenclaure able CHAPTER Diagnosics ables Diagnosics for blades and cus Troubleshooing Willy 225

7 Operaion and mainenance manual for WILLY 225 FOREWORD The machine WILLY 225 is a pendulum bench sawing machine designed for cuing meals. Operaion is manual: afer urning on he elecrical power supply o he machine and clamping he workpiece in he vice, he operaor sars he blade by pressing he microswich locaed on he conrol lever; he hen moves he head downwards in order o cu he maerial; afer compleing he cu, he cuing head reurns o posiion ready for a new cuing cycle. TECHNICAL DATA TABLE WILLY 225 U.M. DATA DISC BLADE Exernal blade diameer - profiles / solid pieces mm 225 Diameer of inernal hole mm 32 Blade hickness mm 2 CUTTING SPEED Sandard speed rpm 50 VALUES OF POWER AND CONSUMPTION Head spindle moor 2-4 poles sd. 2 speed kw 0. Maximum insalled elecrical power kw 0. Oil for lubricaion/cooling liquid (concenraion 5 - %) capaciy kg 0.7 Transmission box oil capaciy L. 2.5 AIRBORNE NOISE Cuing wihou workpiece dba Cuing wih maerial dba Willy 225 1

8 Presenaion INTRODUCTION This working ool has been designed o provide a simple and reliable soluion o he needs of DIY enhusiass and fiers who work wih meals and require a pracical and versaile machine. The WILLY 225, is a compac, lighweigh pendulum sawing machine ha can perform cus angled by 45 o he lef; hese feaures make he WILLY 225 a versaile and economical machine. Congraulaions on choosing he WILLY 225. This machine will give you many years of rouble--free operaion provided you follow he insrucions given in his operaion and mainenance manual. MACHINE SPECIFICATIONS IDENTIFICATION PLATE: The anodied aluminium idenificaion plae is riveed o he side of he machine. IMPORTANT: every ime you conac he Service Cenre make sure you quoe he model, serial number and year of manufacure given on he plae. MODEL WILLY 225 SERIAL NUMBER MEPSPAVia Papa Giovanni XXIII, Pergola (PS) ITALY el: 0721/73721 YEAR OF MANUFACTURE DIMENSIONS: a = 40 mm d b=mm c = 370 mm c b a d = 7 mm weigh = 3 kg CUTTING CAPACITY FOR PROFILES : Cross -secion Blade diameer 0 degrees degrees lef Willy 225

9 CUTTING CAPACITY FOR SOLID PIECES : Cross -secion 0 degrees degrees lef Blade diameer Presenaion Max. opening of cuing vice: 70mm DISC BLADE: Dimensions: HM 225x32x2mm for solid pieces and profiles Cuing speed: sandard 50 r.p.m. SPINDLE MOTOR: Spindle moor: single phase 4 poles; 50 H; IP 54. Characerisics: Volage Vol Absorpion Amp. Power kw r.p.m. 4 poles Saor winding in enamelled copper class H 200 C; Insulaion class F (limi emperaure T L =155 C); Example of class F insulaion : in air--cooled machines a a room emperaure of 40 C (in accordance wih CEI 2--3 and IEC 5) he admissible overemperaure is 0 C (where 0 C represens he admissible T). IP 54 proecion raing (oal proecion agains conac wih live pars and agains waer sprayed from any direcion). Complies wih CEI sandards, IEC publicaion 34 of 1 July 195. Willy 225 3

10 CHAPTER 1 - Funcional pars of he machine In order o gain a good undersanding of he machine, which will be described in deail in he chaper MACHINE OPERATION, we will look a is main unis and heir respecive posiions Lubrican/coolan sysem The lubrican/coolan sysem consiss of a membrane pump driven by a cam mechanical sysem locaed on he shaf ono which he blade is flanged Cuing head The cuing head is he uni ha performs he cu and consiss of a cas iron secion on which he following pars are mouned: he blade, he blade suppor unis, he drive ransmission uni and he spindle moor. The cuing head is fixed o he urnable by means of a hinge and ravels downwards o perform he cu. The upwards and downward movemen of he head is conrolled manually by he operaor Vice The vice is he uni ha holds he workpiece seady during cuing; i consiss of a vice suppor on which he slide wih he mobile jaw and he fixed jaw is mouned. The vice suppor is fixed o he upper secion of he base. 4 Willy 225

11 CHAPTER 2 - Safey The WILLY 225 has been designed and consruced o comply wih European sandards. I is exremely imporan ha you follow he insrucions given in his chaper, as hey are essenial for correc use of he machine Inended use of he machine The pendulum disc sawing machine WILLY 225 is inended o be used exclusively for cuing meal profiles. The machine s specific characerisics make i unsuiable for oher ypes of maerial or process. Personnel raining is he responsibiliy of he employer, who mus inform operaors abou risks of acciden, safey devices, risks relaed o noise emission and general safey precauions laid down by inernaional direcives and legislaion of he counry in which he machine is used. The operaor mus be fully aware of he posiion and operaion of all he machine s conrols. The insrucions, warnings and general safey precauions described in his manual mus be followed compleely by he personnel using he machine. In accordance wih he MACHINERY DIRECTIVE 9/37/CE EEC and subsequen supplemens and amendmens 91/3-93/44-93/, he following definiions are used: ` Danger one : any one wihin and/or around machinery in which an exposed person is subjec o a risk o his healh or safey. CONNECTIONS On he basis of he machine s power absorpion levels given in he Machine specificaions ables on page 2, check ha he elecric and pneumaic power supply lines are able o wihsand he machine s maximum absorpion levels and make any necessary changes. EARTHING SYSTEM The earhing sysem mus mee precise specificaions as prescribed by he IEC STANDARD 204. OPERATOR POSITION The operaor using he machine mus be in he posiion shown in he diagram below Recommendaions for he operaor Always wear adequae safey glasses. ` Exposed person : any person wholly or parially in a danger one. ` Operaor : he person or persons given he ask of insalling, operaing, adjusing, mainaining, cleaning, repairing or ransporing machinery. WARNING: The manufacurer is released from all civil and criminal liabiliy if one or more pars or unis of he machine are ampered wih and/or replaced wihou due auhorisaion, or if any accessories, ools and expendable maerials are used oher han hose recommended by he manufacurer, or if he machine is insered in a complex sysem or i is used in any way ha is differen from he inended use. Do no use he machine wihou he guards in posiion. Do no place your hands or arms in he cuing one while he machine is working or he ool is sill urning General recommendaions LIGHTING A lack of adequae lighing for he inended ype of operaion could lead o risks for he safey of personnel. For his reason he user of he machine mus ensure ha suiable lighing is provided for he working environmen in order o eliminae any areas of shadow or irriaing glare. (Reference sandard ISO Lighing in working environmens ). Do no wear loose--fiing clohing, long sleeves, gloves of he wrong sie, braceles, chains or anyhing else ha migh ge caugh in he machine during operaion; ie back long hair. Always disconnec he machine from he elecrical power supply before carrying ou any mainenance work on he machine or changing he blade. This also applies o operaions ha lie ouside he normal use of he machine. Willy 225 5

12 Safey Before saring o cu, make sure ha he maerial is adequaely suppored on boh sides of he machine. Work may be carried ou on he hydraulic and pneumaic sysems only afer he pressureinside hem has been released. The operaor mus avoid operaions ha are unsafe or no appropriae for he job being performed (e.g. removing swarf from he machine while cuing). When operaing he saw, wear gloves only for handling maerial and for adjusing or changing he blade. Carry ou only one operaion a a ime and do no fill your hands wih more han one objec a he same ime. Keep your hands as clean as possible. Warning: if he blade seies while cuing, immediaely press he machine s emergency sop buon. If he blade does no free, open he vice slowly, remove he workpiece and check ha he blade and he eeh are no broken. If hey are, replace he blade. Before carrying ou any repair work on he machine, conac he MEP service cenre or if necessary is represenaives in he counry in which he machine is used. Clear he cuing area of ools, implemens and all oher objecs; keep he working area as clean as possible. Before saring he cuing operaion, make sure ha he workpiece is held securely by he vice and ha he machine is correcly se up. The following are examples of how differen secion bars can be locked on our sawing machines Machine safey devices This operaion and mainenance manual is no inended o be solely a guide o using he machine for he purposes of producion, bu provides insrucions o ensure ha i is used correcly wih a view o he safey of workers. Below is a lis of he sandards prescribed by he EEC council conained in direcives regarding he safey of machinery, safey a he workplace, personal proecion and environmen proecion. These sandards have been applied o he WILLY Reference sandards SAFETY OF MACHINERY ` EEC direcive no. 9/37/CE of known as he Machinery direcive. ` EEC direcives nos. 91/3;93/44;93/ amending EEC direcive no. 9/37/CE regarding he safey of machinery. ` EEC direcive no. 73/23 known as he Low ension direcive. Do no use he machine for cuing workpieces ha exceed he capaciy saed on he echnical shee. Do no move he machine while i is cuing. Do no use blades wih differen dimensions from hose declared in he machine specificaions. When cuing exremely shor workpieces, make sure ha hey are no dragged behind he res shoulder as his gives rise o a risk of he blade seiing. SAFETY AT THE WORKPLACE ` EEC direcives nos. 0/17; 3/477; /1; /1; /42 relaing o he safeguarding of workers agains risks deriving from exposure o chemical, physical and biological agens during work. ` EEC direcive no. 9/391 and Special EEC direcives no. 9/54 and no. 9/55 relaing o he improvemen of healh and safey of workers a work. ` EEC direcive no. /394 relaing o he safeguarding of workers agains risks deriving from exposure o carcinogenic agens during work. ` EEC direcives no. 77/57 and no. 79/40 regarding safey signs a he workplace. INDIVIDUAL PROTECTION ` EEC direcives no. 9/5 and no. 9/ regarding he use of individual proecive devices. ENVIRONMENT PROTECTION ` EEC direcive no. 75/442 regarding wase disposal. ` EEC direcive no. 75/439 regarding he disposal of used oil. Willy 225

13 Proecion agains accidenal conac wih he blade Airborne noise from he machine Safey Noise causes damage o hearing and is a problem ha many counries ackle by laying down specific regulaions. In conformiy wih he regulaions esablished by he Machinery Direcive 9/37/CE/EEC, we hereby inform you of he sandards prescribing he sound level hreshold for machine ools. This chaper provides he values of airborne noise levels generaed by he WILLY 225 in he various sages of is operaion and he mehod used for measuring he sound level values. This siuaion is regulaed in ITALY by he D.M.no.277/91 which has adoped he Communiy Direcives 0/17/EEC, 2/05/EEC, 3/477/EEC, /1/EEC, /42/EEC Mehods of measuring sound level values Meal blade guard fixed o he cuing head; mobile blade guard aached o he fixed guard and he machine body o ensure ha he blade is covered and ha only he par of he blade engaged in cuing is lef free, as prescribed by he DPR 547/55 ar Elecrical equipmen In accordance wih he Ialian sandard CEI , Sepember 1993, deriving from he European sandard EN IEC publicaion , 1992: - Accessibiliy o he elecrical panel resriced by screws; - earhing of all pars subjec o risk of conac accidenally or during work; - he power supply secioning device realised wih a socke/plug combinaion in accordance wih sub--secion c Noise level values The sound level measuremens are carried ou using an insrumen called an Inegraing sound level meer which serves o measure he weighed equivalen coninuous sound pressure level a he workplace. The damage caused by noise depends on hree facors: level, frequency disribuion and duraion. The concep of equivalen level L eq combines he hree facors so as o provide jus one simple parameer. The L eq is based on he equal energy principle and represens he coninuous saionary level wih he same energy conen, expressed in dba, as he real flucuaing level in he same period of ime. This calculaion is performed auomaically by he inegraing sound level meer. Each measuremen lass for 0 seconds o allow he value o sabilise; he value obained remains on he display o give he operaor ime o read i. Measuremens are made wih he equipmen held a a disance of abou 1 mere from he machine and a a heigh of 1.0 m from he operaor s workplace plaform. Two measuremens are made: he firs while he machine is performing a manual cu wihou a workpiece; he second while he maerial is being cu manually. Idenificaion Machine ype Band saw for meal applicaions Model WILLY 225 Reference sandard ISO 374 Tes 1 Tes 2 Tes 3 Descripion Resuls Descripion Resuls Descripion Resuls Resuls 50x15 mm pipe in FE37 seel Disc blade HSS -DMO5 Ø 225x32x2 MEAN SOUND LEVEL (L eq ) 1.25 db (A) Environmenal correcion (K) 2.7 db(a) Peak sound power (Lw) db(a) 35 mm Ø solid ube in FE37 seel. Disc blade HSS -DMO5 Ø 225x32x2 MEAN SOUND LEVEL (L e q) 93.1 db(a) Environmenal correcion (K) 2.7 db(a) Peak sound power (Lw) 2.34 db(a) 20 mm Ø solid ube in FE37 seel. Disc blade HSS -DMO5 Ø 225x32x2 MEAN SOUND LEVEL (L eq ) 9.7 db(a) Environmenal correcion (K) 2.7 db(a) Peak sound power (Lw) 9.40 db(a) Willy 225 7

14 CHAPTER 3 - Insalling he machine Unpacking he machine MEP S.p.A. uses packaging ha is appropriae for proecing he machine from damage during ranspor righ up unil he ime i is delivered o he cusomer. The ype of packaging used for he machine depends on he dimensions, weigh and desinaion, so he cusomer will receive he machine in one of he wo following ways: - package including palle, sraps and cardboard box wih lid. Before insalling he machine, remove he packaging, aking care no o cu elecric cables or hydraulic hoses and using pliers, a hammer and a cuer as required. To place he machine in is working posiion, follow he insrucions given in paragraph 3.4. The working posiion mus be chosen aking ino consideraion he machine dimensions and he space required o allow he operaor o perform all necessary manoeuvres o ensure his safey Check lis Before beginning o insall he machine, check he sandard and opional accessories provided wih he machine. The sandard version of he WILLY SPEED sawing machine is supplied complee wih: ` pedesal wih ank for coolan; ` membrane pump for lubricaion and cooling of blade; ` IP 55 head conrol lever; ` mobile guard o cover par of blade no engaged in cuing; ` roaing head wih screw locking faciliy o perform angled cus; ` possibiliy of performing cus from 0_ o 45 o he lef; ` 1 speed single--phase elecric moor; ` bag of accessories. The bag of accessories is enclosed in he machine before packaging and conains he following accessories: ` 4, 5,, mm Allen keys; ` rod for measured cus; ` his operaion and mainenance manual; - package wih palle, cardboard boxes (for more han one machine) and wooden crae. OPTIONAL ACCESSORIES AVAILABLE ON REQUEST: ` HSS DMo5/M2 D.225x32x2 circular blade for cuing solid bars and profiles; ` 5 l can of emulsible oil Minimum requiremens The following are he minimum environmenal requiremens needed o ensure correc operaion of he machine: -- mains volage / frequency: see values given on he daa plae; -- room emperaure: from -- o + 50 C; -- relaive humidiy: no higher han %; -- room lighing: no lower han 500 Lux. WARNING! Alhough he machine is proeced agains volage variaions, good operaion can only be ensured by sable volage, which should no vary by more han %. In eiher case, lif he machine using a fork lif ruck, insering he forks a he poins marked by he arrows and following he insrucions given on he box. WARNING! Do no handle he packaged machine by harnessing wih a sling. NO Willy 225

15 3.5 - Connecing elecrical power supply Before connecing he machine o he elecrical power supply, check ha he power socke is no conneced in series wih oher machines. This is essenial in order o ensure good operaion of he machine. To connec he machine o he mains elecric power supply proceed as follows: 1 -- connec he machine s power cable o a plug which is suiable for he socke you have decided o use, EN para Inser he plug in he socke, checking ha he mains volage corresponds o he volage he machine was designed for. Insalling he machine 4 -- Check ha he moor urns in he correc direcion.todohis, proceed as follows: a) press he jog buon on he head conrol lever; b) if he operaions have been performed successfully, he blade moor will sar up and he blade will sar o urn. VOLT? VOLT? 3 -- Press he red buon on he blade moor box. The buon lighs up and he machine is now on STAND--BY. Check ha he blade urns in he righ direcion as shown in he diagram. The saw is now ready o sar work. See Chaper 4 for a deailed descripion of he operaion of he machine. Willy 225 9

16 CHAPTER 4 - Machine operaion In his chaper we will look a all he funcions of he machine, saring wih a descripion of he conrol panel buons and componens Descripion of conrols The drawing below shows he conrols of he WILLY 225; each numbered arrow corresponds o a descripion given in he following ex. 1 2 Head conrol lever. 1 - ON/OFF SWITCH 2 - HEAD CONTROL LEVER MICROSWITCH The microswich conrolling he blade moor is locaed on he head conrol lever knob. Operaing lever Microswich Press his buon o urn on he power supply o he machine. The swich lighs up when i is in he ON posiion, leing he operaor know ha he machine is on sand--by. Providing no emergency condiion has occurred, his is enabled when he machine is urned on. The volage is 24 Vol in accordance wih applicable legislaion. The microswich is mouned in an enclosure (blue knob) isolaed from exernal agens, such as dus and humidiy, wih a proecion raing of IP 55. Willy 225

17 4.2 - Manual operaing cycle Sequence of operaions o be performed when making any cu: 1) Turn he machine s power supply on by pressing he ON/OFF swich. 2) Place he maerial inside he vice and calculae he lengh of he cus (using he rod for measured cus). 3) Clamp he workpiece in he cuing vice. ) The moor sars, causing he blade o urn. A he same ime he lubrican/coolan pump sars up. 7) When he cu is compleed, move he head back upwards. Machine operaion 4) Make sure he workpiece is securely clamped in he vice by rying o move i manually. 5) Grip he head conrol lever and sar he blade urning by pressing he microswich on he handgrip; he head is guided manually by he operaor a he desired speed. ) Free he workpiece from he vice by urning he handwheel. The machine is now ready for a new operaion. Willy

18 Schemi, esplosi e ricambi Esplosi La pare che segue riguarda i disegni esplosi che, daa la compleea dei paricolari, possono aiuare nel conoscere più a fondo quesa macchina Gruppo esa Willy 225

19 Ricambi Schemi, esplosi e ricambi Codice Descriione U.M. Q.à CODICI DEI COMPONENTI TESTA WY 91 TEMP. NR 1, CARTER DISCO NR 1, FLANGIA DISCO NR 1, TAPPO ANTERIORE WY TEMP. NR 1, BOCCOLA X ECCENTRICO POMPA NR 1, VITE COMANDO PROTEZIONE NR 1, LEVA COMANDO TESTA NR 1, ANELLO SEEGER DIAM. 45 US.0.01 NR 1, CHIAVETTA 5 X 5 X 30 NR 1, DADO M NR 2, DADO M1 BASSO NR 1, DADO AUT. M17 BASSO NR 1, RONDELLA DIAM. 4 NR 2, RONDELLA DIAM. 5 NR 4, RONDELLA DIAM. NR 1, RONDELLA DIAM. NR 4, RONDELLA DIAM. NR 1, SPINA CONICA DIAM. X 35 NR 1, SPINA ELASTICA DIAM. X 20 NR 1, VITE BUTON 5 X NR 2, VITE TCEI 4 X NR 2, VITE TCEI 5 X 15 NR 3, VITE TCEI X NR 2, VITE TCEI X 1 NR 1, VITE TCEI X 30 NR 1, VITE TE X 25 NR, ALBERO PORTADISCO NR 1, ASTA COMANDO PROTEZIONE NR 1, SUPPORTO POMPA NR 1, SQUADRETTO COMANDO POMPA NR 1, PROTEZIONE COMANDO POMPA NR 1, HP 2/2,5 2/4P V.30 B FCL NR 1, HP 1 V.220 MON.4PSB5 FLANG.TEMP.WY NR 1, VITE SENZA FINE NR 1, CORONA ELICOIDALE NR 1, ANELLO TENUTA 35X25X7 NR 3, ANELLO DI TENUTA OR 211 NR 1, GUARNIZ.MOTORE NR 1, BOCCOLA A RULLINI INA HK 15 NR 1, POMPET.LUBRIF NR 1, PROTEZIONE DISCO NR 1, TAPPO LIVELLO OLIO SLNT 3 3/ NR 1, IMPUGNATURA DIS. MEP NR 1,000 Willy

20 Schemi, esplosi e ricambi Gruppo morsa Willy 225

21 Ricambi Schemi, esplosi e ricambi Codice Descriione U.M. Q.à CODICI DEI COMPONENTI PIANO GIREVOLE NR 1, GANASCIA MORSA NR 1, PIATTAFORMA FISSA CON MORSA NR 1, PERNO SUPPORTO SNODO TESTA NR 1, ASTA BATTUTA TAGLI A MISURA NR 1, DISTANZIALE BATTUTA NR 1, PERNO BATTUTA TAGLI A MISURA NR 1, VITE MORSA NR 1, MOLLA RICHIAMO TESTA NR 1, VITERIA E BULLONERIA NR 1, TASSELLO FIX PIANO GIREVOLE NR 1, ANELLO SEEGER DIAM. 25 NR 2, GRANO VCE P.CIL. X NR 1, GRANO VCE PUNTA PIANA X NR 1, RONDELLA DIAM. 5 NR 2, RONDELLA DIAM. NR 2, RONDELLA DIAM. NR 1, SPINA ELASTICA DIAM. X 35 NR 1, SPINA ELASTICA DIAM. X 20 NR 1, VITE TCEI 5 X NR 2, VITE TCEI X NR 2, VITE TCEI X 20 NR 4, VITE TE X 50 NR 1, RACCOGLITORE ACQUA MORSA CON VASCA NR 1, SUPPORTO FISSO COMANDO PROTEZIONE NR 1, COPERCHIO MORSA NR 1, TUBO PLASTIFICATO 04- KG 0, VOLANTINO MORSA PICCOLO NR 1, VOLANTINO DIAM.30 M X NR 2,000 Willy

22 CHAPTER 5 - Drawings, exploded diagrams and spare pars This chaper provides he funcional and exploded diagrams for he WILLY 225. This documenaion will help you locae he pars ha make up he machine so as o allow you perform repair and/or mainenance work; i will also enable you o indicae he spare par you require wihou any risk of misundersanding by defining i correcly wih is posiion number and code Diagrams Elecrical diagrams SCREEN MAGNETO -THERMAL SWITCH (D) MEP 9 CONTROLLER (Code ) STRAIN GAUGE (Code ) CPU CARD TERMINAL BOARD THERMAL CUTOUT MAGNETO -THERMAL SWITCH + EMERGENCY SWITCH + LIMIT SWITCH (D) MAGNETO -THERMAL SWITCH + EMERGENCY SWITCH MECHANICAL CLOSURE COIL TIMER (Code ) TERMINAL + FUSE SHORT CIRCUIT CUTOUT MAE HY MOTOR (Code ) ELECTRIC PUMP (Code ) FREQUENCY CONVERTER (Code ) DIGITAL AMMETER (Code ) TERMINAL BOARD ARRANGED IN GROUPS OF THREE TERMINALS TERMINALS MAIN MOTOR (Code ) JAPAN SERVO KP MOTOR (Code ) REMOTE -CONTROL REVERSER AUXILIARY TERMINALS TERMINAL BOARD 1 Willy 225

23 GENERAL KEY TO STANDARDISED ELECTRICAL DIAGRAM COMPONENTS (CENELEC STANDARDS) Drawings, exploded diagrams and spare pars VICE OPENING/CLOSING BUTTON (Code ) (Code ) EMERGENCY BUTTON (Code ) (Code ) SELECTOR (2 Pos. Code ) (3 Pos. Code ) COOLING FLUID SELECTOR NORMALLY OPEN CAM MULTIPLE BUTTON NORMALLY CLOSED CAM MULTIPLE BUTTON MICROSWITCH (Code ) LIMIT SWITCH (Code ) PRESSURE SWITCH (Code ) PEDAL UNIT (Code ) SAFETY LIMIT SWITCH (Code ) SOLENOID VALVE (3 way Code ) (5 way Code ) LED DIODE (24 Vol. 24 Code ) (Vol 1 Code ) POLARITY SWITCH (Code ) ELECTRIC PUMP ANTIDISTURBANCE FILTER (Code ) MOTOR CONTACTOR (Code ) CONTROL COIL (Code 022.0) POTENTIOMETER (Code ) TRANSFORMER (Code ) MEP 11 CONTROLLER (Code ) IUV CARD (Code ) IUV DIGITAL IN/OUT CARD 1 IUV DIGITAL IN/OUT CARD 2 OPU CARD (Code ) Willy

24 Drawings, exploded diagrams and spare pars STANDARDISED ELECTRICAL DIAGRAMS (CENELEC STANDARDS) 20 Willy 225

25 CHAPTER - Adjusmens This chaper provides he insrucions o follow when adjusing he mechanical sysems of he WILLY 225 in order o use he machine correcly. These insrucions allow you o cusomise your machine and keep operaing imes down o a minimum..1 - Blade The HSS cuing discs can be used for any ype of cu as hey combine exremely high oughness and elasiciy obained by means of a number of empering reamens, and also offer good cuing resisance. The discs are made of a single piece of ungsen molybdenum seel wih a hardness of abou 4 1 HRC. These blades ensure ha he cu surfaces have a good finish Performing angled cus -- he machine is now ready for performing cus angled by 30 o he lef. The WILLY 225 can perform cus angled a 45_ o he lef. The following operaion is necessary o perform a cu angled by 30_. -- Free he urnable by means of he locking screw locaing beween he vice and he moor suppor on he urnable iself;.2 - Changing blade -- wih he urnable free, urn he machine body o he desired angle (30_), reading off he posiion on heangle scalelocaed on he boom secion of he urnable. As we have already seen, his machine uses various ypes of blade depending on he maerial ha has o be cu. However he following operaions are he same for he various ypes of blade and also apply in he even of wear or breakage of he ool. In order o replace, proceed as follows: -- urn off he power supply o he machine; -- free he mobile blade guard by removing i from he eccenric rod (1); -- move he mobile guard upwards (2); -- loosen he blade locking nu using a mm Allen key; -- o undo he blade locking nu, urn i in he direcion of disc roaion; -- Once you have reached he desired angle, secure he machine body by ighening he locking screw; -- remove he blade which needs o be replaced (because of wear or for oher reasons) and inser he new blade, repeaing he above operaions in reverse order. The above procedures are exacly he same when he ool has o be replaced because i is worn or broken. Do no perform he above operaions wihou firs urning off he elecrical power supply o he machine! Falcon

26 CHAPTER 7 - Mainenance and choice of expendable maerials The WILLY 225 is a robus machine ha ensures a good lifeime. I does no require any special mainenance alhough, like all machine ools, i is liable o deeriorae wih ime, especially if i is badly used and no serviced correcly. This chaper herefore serves as a reminder o users who wish o keep heir machine in good working order and hus ensure ha i provides saisfacory operaion for as long as possible Role of he operaor responsible for he machine The person responsible for he operaion and mainenance of he machine mus follow hese insrucions in order o guaranee heir safey and ha of ohers and o ensure saisfacory operaion of he machine: - use he safey devices correcly and comply wih he prescribed safey sandards when working wih he machine and ensure ha oher operaors do so; ensure ha he safey devices are correcly posiioned and operaive and ha he individual safey sandards are complied wih. - make sure ha he machine performs he working cycle correcly so as o ensure maximum produciviy, checking: -- ha he main machine pars operae correcly; -- ha he blade is sharp and he flow of cooling liquid is correc; -- ha he opimal working parameers for he ype of maerial are complied wih. - ensure ha cuing qualiy is saisfacory and ha he final produc does no show any machining defecs Recommendaions for mainenance - All rouine and special mainenance operaions mus be carried ou wih he plug disconneced from he power supply. - To ensure perfec operaion only MEP S.p.A. original spare pars mus be used. - When mainenance work is finished, make sure ha he replaced pars and any ools used have been removed from he machine before saring i up again. - Any operaions oher han hose described in he insrucions for use and mainenance of he machine may be haardous for he operaor. - I is herefore essenial o read and observe all he insrucions for he use and mainenance of his machine and any insrucions regarding he produc iself General machine mainenance Daily This secion liss he daily mainenance procedures o be carried ou on he machine: -- remove all swarf from he machine (using compressed air and preferably hread--free rags); -- op up wih lubrican/cooling liquid o he required level; -- check he blade for wear and if necessary replace Weekly This secion liss he weekly mainenance procedures o be carried ou on he machine: -- clean he machine of all swarf; -- clean he vice and lubricae all he joins and sliding surfaces, preferably using good qualiy oil; -- check he oil level in he ransmission box; if necessary fill up via he plug; -- check he sliding movemen of he vice; if i is no precise and shows ransversal play, adjus Monhly This secion liss he monhly mainenance procedures o be carried ou on he machine: -- check ha he machine performs cus perpendicular o he work able; if no, conac our service cenre; -- check ha he blade is perpendicular o he workpiece res shoulder; if adjusmen is required, conacour servicecenre; -- clean he waer ank and he lubricaion pump filer horoughly Mainenance of working unis The person responsible for carrying ou mainenance on he WILLY 225 mus give paricular aenion o working unis such as he ransmission box Transmission box Transmission box mainenance: -- afer he firs 0 hours of work, empy he ransmission box via he discharge plug on he boom fron secion of he uni and replace all he oil. If impuriies can be observed in he oil, ake off he lid and clean inside horoughly. Use washing oil o do his; avoid drying wih coon or sringy rags. Fill he ransmission box wih oil; -- replace he oil subsequenly afer every 2000 hours of work Expendable maerials I is essenial o use oils specifically designed for he lubrican/ coolan circui. Below is given a lis of oils ha are suiable for his circui Transmission box oils The machine is supplied wih AGIP BLASIA 40 ype oil, ISO and UNI symbol CC 40; however he following is a lis of suiable oils ha have equivalen characerisics: API DT CASTROL Alpha SP ARAL Degol BG 40 ARCO PENNANT NL BP Energol GR/XP ELF Reducelf SP ESSO Sparan EP 40 Transmission box: -- ransmission box capaciy 0.7 kg Oils for he lubrican/coolan fluid The ype of oil used for he machine s lubrican/coolan fluid is CASTROL Synolin TFX. In he absence of any specific legislaive requiremens, MEP has chosen his produc as i is he one ha provides he bes qualiy/price raio. In any case he following is a lis of suiable oils ha have equivalen characerisics: AGIP NB SHELL Luem TT -- IP Uens Fluid--F Cooling fluid ank: -- ank capaciy 2.5 L. -- Oil concenraion 5-- % 22 Willy 225

27 CHAPTER - Choice of blades When using he WILLY 225 pendulum saw i is imporan o selec he correc ype of blade for he maerial o be cu. This chaper explains he limiaions and specific applicaions of he differen ypes of blades..1 - Choice of blade A larger pich should be chosen when he cross--secion a any given poin exceeds he average cross--secion given above as a resul of he shape of he piece o be cu. Type of swarf: A -- Very fine or pulverised swarf indicaes an excessively low feeding speed and/or cuing pressure. The differen ypes of blades ha can be used on he WILLY 225 mus saisfy he following general requiremens: - FINE TOOTH PITCH -- for hin walled maerials such as seel plae, ubes and profiles; - COARSE TOOTH PITCH -- for large cross--secions; -- for sof maerials (aluminium alloys and sof alloys in general); Tooh pich The choice of he mos suiable ooh pich depends on a number of facors: a) he sie of he secion; b) he hardness of he maerial; c) he wall hickness. Solid secions require discs wih a coarse ooh pich, whereas small cross--secions need blades wih finer eeh. This is because when walls of small cross--secion (17 mm) profiles are cu, i is imporan ha he number of eeh acually making he cu is no oo small, oherwise he effec obained will be one of earing raher han of swarf removal, leading o a large increase in shearing sress. On he oher hand, when cuing hick maerials or solid secions using a blade wih an excessively fine ooh pich, he swarf collecs as a spiral inside he gulle, and since fine ooh piches have small gulles, he accumulaed swarf will exceed he gulle capaciy and press agains he walls of he workpieces, resuling in poor cuing (same siuaion wih sof maerials), greaer shearing sress and hence breakage of he blade. Choice of ooh pich T as a funcion of cross -secion o be cu S S sp Sinmm PichT for seel solid pieces and profiles S and sp in mm Pich T sp= sp= sp= sp= sp= sp=.5 KEY: s = diameer or widh of he solid piece o be cu in mm sp = hickness of he wall o be cu in mm T = ooh pich in mm B -- Thick and/or blue swarf indicaes ha he blade is overloaded. C -- Long, spiral swarf indicaes ha cuing condiions are ideal Cuing and feeding speed The cuing speed in m/min and he feeding speed in cm 2 /min are limied by he amoun of hea generaed near he poins of he eeh. If he feeding speed is oo high, he cu will no be sraigh in eiher he verical or he horional plane. As we have already seen, he cuing speed depends on he resisance (kg/mm 2 )and hardness (HRC) of he maerial and he dimensions of he hickes secions. The feeding speed depends on he cross--secion of he maerial. This means ha large cross--secion solid or hick--walled maerials (s > 5 mm) can have a high feeding speed provided here is sufficien swarf removal by he blade; hin--walled maerials, such as hin pipes or profiles, mus be cu wih a low and above all consan feeding speed. A new blade requires a wearing--in period, during which ime a feeding speed of abou half normal speed should be used Lubricaing/cooling fluid The lubricaing/cooling fluid mus ensure ha he blade eeh and maerial in he cuing area do no overhea. Furhermore he fluid mus be supplied wih a sufficien quaniy and pressure o remove he swarf from he cuing area. I mus be an excellen lubrican o preven abrasion of he eeh and welding of he swarf o he eeh (seiing). Willy

28 Choice of blades Blade srucure The mos widely used disc blades for sawing machines are made of a single piece of HSS--DMo5/M2 characerised by a high level of oughness and good cuing resisance. For non--ferrous maerials, on he oher hand, i is common o use circular blades wih a braed hard meal HM cuing edge, which have shown excellen wear resisance bu low resisance o impac, which is in any case a minor problem wih non--ferrous maerials. CHEMICAL COMPOSITION : C TYPE OF BLADE HSS- DMo5/M2 Cr W Mo V Co HRC Coarse oohing wih roughing ooh and finishing ooh. Used on saws wih pich greaer han or equal o 5 mm for cuing ferrous and non--ferrous maerials wih solid or solid--profiled secions. 4+/--1 KEY: C = Carbon Co = Cobal Cr = Chromium Mo = Molybdenum W = Tungsen V = Vanadium The numbers in he columns indicae he % of he elemen presen in he seel. BW TYPE SHARPENING DIN 13--UNI 40 Coarse oohing wih eeh alernaely raked o he righ and o he lef Types of blade The blades fied on he WILLY 225 have dimensions 225x32x2 and are made of HSS DMo5 since he machine is o be used for cuing ferrous maerials. In addiion o he sie and pich of he eeh, however, he blades also have differen geomeric characerisics in accordance wih heir specific use: - ooh sharpening, which in his case may be BW wih an alernae raked ooh or C wih a roughing ooh raked on boh sides and a non--raked finishing ooh. - ooh pich, he disance beween he cres of one ooh and he cres of he nex ooh (ooh pich = T). Shape of eeh: C TYPE SHARPENING (HZ) Coarse oohing wih roughing ooh raked on boh sides and non--raked finishing ooh. The roughing ooh is abou 0.3 mm higher. Toohing generally used on sawing machines for cuing ferrous maerials and alloys wih ubular and profiled secions. The WILLY 225 uses 225x2x32 blades made of HSS DMo5 and wih C ype sharpening eeh for hollow secions. For solid secions, on he oher hand, i uses blades of he same dimensions bu wih a differen ooh pich, as shown in he able below. Table for choosing blades for he machine WILLY 225; oher blade characerisics are: dimensions -inernal hole 32, disance beween fixing holes 3; ooh shape ype C. Hollow profiles wih hickness from 1 o 5 mm WILLY Hollow profiles wih hickness from 5 o mm D. T Z Solid secions wih dimensions ha do no exceed he cuing capaciy D. T Z D. T Z Willy 225

29 Choice of blades Willy This able can be used o faciliae he choice of oohing since i akes ino accoun boh he sie of he maerial o be cu and he diameer of he blade. HOLLOW SOLID SECTIONS S D D S D S SECTIONS S=0.005xD

30 Choice of blades.1. - Recommended cuing parameer able Av mm/min. RECOMMENDED LUBRICANTS V m/min. Tmm Av mm/min V m/min. Tmm SECTION TO BE CUT (IN MM) V m/min. Av mm/min. Tmm V m/min. Av mm/min. Tmm V m/min. Av mm/min. Tmm Av mm/min V m/min. Tmm Av mm/min V m/min. Tmm CUTTING ANGLES α γ RECOMMENDED CUTTING PARAMETERS Emulsion -- Cuing oil Cuing oil Emulsion Mild seel R = N/mm2 Medium seel R = N/mm2 Hard seel R = N/mm2 Super hard seel R = N/mm2 Hardened and empered seel R = N/mm2 Auseniic sainless see R = N/mm2 Mar. sainless seel R = N/mm2 Grey iron Aluminium and alloys R = N/mm2 Aluminium and alloys R = N/mm2 Copper R = N/mm2 Gun meal R = N/mm2 Phosphor brone R = N/mm2 Brass R = N/mm2 Alloy brass R = N/mm2 Tianium and alloys R = N/mm2 Profiles and pipes wih wall hickness 0.05 D R = N/mm2 Profiles and pipes wih wall hickness 0.25 D R = N/mm2 2 Willy 225

31 .2 - Classificaion of seels Choice of blades This page gives ables ha provide he user wih specific informaion on he maerial o be cu. This enables hese maerials o be classified according o heir hardness and herefore ensure ha he righ blade is used. Type of seel Hardness UNI DIN BS AISI Brinel HB Rockw. Kg/mm2 C22--C35 C45 C--C15 C0 45 Cr Si 9 34 Cr Mo 5 35 Cr Mo 4 20 Nc Cr Mo 2 0 Cr 52 Nc Cr Mo KU XCr13 X Cr Ni 1 X Cr Ni 19 X Cr Ni Mo 1713 Phosphor brone Aluminium brone Manganese brone Silicon brone CK CK 3 CK 45 CK -- CK 15 CK Cr Mo 3 Ni Cr X C 95 0 Cr 5 Ni Cr Mo V (20W1) 2 Cr En2C--En En En 32 A -- En 32 En A En 20 A En 1 B En 19 B En 111 En 3 En 32 En 0 D DX En 31 B2 1 % W A2 A1 En 5 G En 5 A En 5 E ASTMA -- 3/ W1 520 L T1 13 M13 D3 309 S Seel nomenclaure able Maerial SS Sweden AISI U.S.A. DIN Germany BS UK UNI Ialy AFNOR France Carbon seels Carbon seels Alloy seels Alloy seels C22--C35 20 Mn Mn CK CK 50 CK 0 -- CK 1 3 Mn 5 Cm Cm 55 25CrMo4--42CrMo4 40 Ni Cr Mo 40 Ni Cr Mo Cr Ni Mo, 0 Cr 050 A M M M 2 00 A A M A A CDS 1 70 A M A 50, 534 A M ypes and 7 C15--C35 C22Mn C2Mn C45--C0 25CrMo4--42CrMo4 40 Ni Cr Mo Ni Cr Mo 7 30NiCrMo--35NiCrMoKB 50 Cr V 4, 0 Cr XC 1 XC 3 H 1 20 M 5 XC 0 -- XC M 5 XC 42 H 1 XC 55 H 1 25 CD 4 42 CD 4 35 NCD 50 CV 4 0 C Tool seels D--2,D--3 X 2 Cr X155CrVMo1 BD 2, BD 3 X 205 Cr KU X 155 Cr V Mo 1 KU Z 10 CVD Z 200 C Tool seel S--1 0 W Cr V 7 55 Ni Cr Mo V BS 1 55 W Cr V Ku 55 Ni Cr Mo V 55 NCVD 7 Sainless seels , , 304 X 2 Cr Ni 19 X 5 Cr Ni 19 G -- X 2 Cr Ni S C 304 S X 2 Cr Ni 1.11 X 5 Cr Ni 1. G -- X 2 Cr Ni 19. Z 2 CN 1. Z CN 1.09 Z 3 CN 19. Sainless seels , X 15 Cr Ni Si 2520 X 5 Cr Ni Mo 1 X 5 Cr Ni Mo S S 1 X1CrNiSi2520 X 5 Cr Ni Mo 1713 X 5 Cr Ni Mo 115 Z CNS Z CND 17. Willy

32 CHAPTER 9 - Diagnosics ables This chaper describes he inspecion and roubleshooing procedures required for he WILLY 225. Regular inspecion and adequae mainenance of he machine are essenial in order o guaranee a long working life for he machine and rouble--free operaion. This chaper consiss of wo secions: he firs secion, DIAGNOSTICS FOR BLADES AND CUTS, is inended specifically for solving problems relaing o blades and cus; he second secion, TROUBLESHOOTING, aims o diagnose general machine operaing fauls. By using his roubleshooing guide you can ake he acion needed o solve problems Diagnosics for blades and cus PROBLEM PROBABLE CAUSE SOLUTION Cus no perpendicular or angled Head descen speed oo fas Reduce head descen speed Blade wih worn eeh Replace blade. Perpendiculariy of blade o workpiece res shoulder If his does no solve he problem, conac our Technical Service Cenre. Perpendiculariy of blade o workpiece res able If his does no solve he problem, conac our Technical Service Cenre. Broken eeh Check he hardness of he maerial you are cuing. Teeh broken Incorrec lubricaion/cooling fluid Check he waer and oil emulsion; check ha he holes and he ubes are no blocked. Maerial oo hard Check he feeding speed and he ype of blade you are using. Blade no worn--in correcly Wih a new blade i is necessary o sar cuing a half he usual feeding speed. Afer a wearing--in ime (abou 300 cm 2 for hard maerials and abou 00 cm 2 for maerials wih a sof cuing surface) he feeding speed can be increased o normal values. Blade wih excessively fine oohing The swarf builds up a he boom of he eeh, giving rise o an excessive pressure on he eeh. Inroducing a new blade ino a parially compleed cu The cuing surface may have undergone a local hermal aleraion increasing is hardness: resar wih lower cuing and feeding speeds. A ooh from he replaced blade may have remained in he cu: check and remove he ooh before resuming work. 2 Willy 225

33 Diagnosics ables PROBLEM PROBABLE CAUSE SOLUTION Workpiece no sufficienly clamped If he workpiece moves during he cu i can cause he eeh o break: check he vice, he jaws and he pressure you use o clamp he workpiece. Vibraions Workpiece vibraing in he vice: check ha he slide is correcly adjused; check he pressure you use o clamp he workpiece. Rapid wear of eeh Feeding speed oo low The blade runs over he maerial wihou removing i: increase feeding speed Lack of coolan Incorrec concenraion of he fluid Check he coolan level and clean hoses and noles. Check and use he correc concenraion. Maerial fauls The maerial may presen alered areas boh on he surface, such as oxides or sand, and wihin he secions, such as undercooled inclusions. These ones, which are much harder han he blade, cause he eeh o break: discard or clean hese maerials. Broken blade Feeding speed oo high Reduce he feeding speed. Teeh in conac wih he maerial before saring he cu Always check he posiion of he blade before saring a new job. Lack of coolan Check he coolan level and clean he hoses and noles carefully. Vibraions Workpiece vibraes in he vice: check ha he slide is correcly adjused; check he pressure you use o clamp he vice; increase if necessary. Willy

34 9.2 - Troubleshooing This secion serves o solve problems which may arise during he operaion of he WILLY 225. PROBLEM PROBABLE CAUSE SOLUTION SPINDLE MOTOR DOES NOT TURN Elecrical power supply Check: he phases; he cables; he plug; he socke. Also check ha he moor connecions are correcly placed. Moor Check ha i has no burned ou, ha i urns freely and ha here is no moisure in he connecing erminal board box. Rewind or replace. 30 Willy 225

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