CHIAO SHENG MACHINERY

CT-375
MANUAL BOOK

No.2 , Sec.2, Huandong Rd., Tainan Science Park Sinshih Township,

Tainan County 74144, TAIWAN, R.O.C.

TEL:+886-6-5055800 FAX:+886-6-5055798
HOME PAGE: http//www.tubebender.com.tw
E-MAIL: [email protected]

CE305-TX V1.200
 Doc. No. CE305-TX
Chiao Sheng Machinery Co., Ltd. Version V1.200
Issue Date 2010/01

WARNING!
 Don't modify any systems and components of machines without the authorization and
permission of administrators in the Technology Department of CSM
 People who modify machines without the authorization will be canceled the rights and the
guarantee of Chiao Sheng Machinery Co., Ltd.
 Don't modify the safe system and electric system of machines to make sure the safety of
operators.
 Operators must read this handbook first before operating or installing components of machines,
in case of the inexactitude installation and operation cause the danger of operators and the
damage to machines.
 Don't issue this handbook to other individuals, companies or organizations.
 Don't copy this book in any form.
 People who draw this stuff should know to limit issuing the documents in the company.

Attention !
 You have to check every part and component of the machine when you receive it. If there are
some damage to machines or the lost parts during the delivery, please contact the ship
company immediately to ask the indemnification of the damage and the lost parts.
 This handbook can offer the regulation of delivering, installing, safety operation, and explain of
operation, the adjustments of the molding tools, maintenance, and excluding malfunction of the
automatic cutting machine.

The Usage of Cutting Machine

 Please use the cutting machine with rational and careful attitude to keep the safety of the
operators and elongate the time limit of the machines.
 In the case of the function of machines, the manufacture of the cutting machine is very
enhanced.
 Correct usage and maintenance with a good plan can help to elongate the using time limit of
machines. However, artificial fault and unpractical maintenance will cause machines get
serious damage during the operation procedure, and accelerate the wear of components, even
endanger with operators seriously.
 This cutting machine just could be used to cut the metal material tubes. Please don’t try to cut
non-metal material. If the operators use this cutting machine to do other uses, it would be
dangerous.
 If you don’t obey this regulation and cause some damage, you will lose the rights and the
warrantee of Chiao Sheng Machinery Co., Ltd.
 Doc. No. CE305-TX
Chiao Sheng Machinery Co., Ltd. Version V1.200
Issue Date 2010/01

Index

Page
Part Ⅰ The Transportation And The Regulations for Installing Cutting Machine
1 Packing And Transportation …...……….…………………………….…..…………… Ⅰ- 3
2 Installing The Machine ……...………………….…………………………..…... …….. Ⅰ- 4
3 The Choice of Oil Sorts ……………………….……………………….……..………… Ⅰ- 5
4 Cooling System ……………………………….…………………….………..….. ……. Ⅰ- 8
5 Electrical System ……………………..…………………………..….………..……….. Ⅰ- 9
Part ⅡSafety Section
1 Safety Warning Label…………………………………………………………..….. …….. Ⅱ-4
2 General Information……………………………………………………………..…. …….. Ⅱ-10
3 Electrical, Safety Practices……………………………………………………..………… Ⅱ-12
4 Hydraulics, Safety Practices…………………………………………………..…. ……… Ⅱ-13
5 Noise Levels……………………………………………………………………..….. ……. Ⅱ-14
6 AC Servo Driver, Safety Practices …………..………………………………..…………. Ⅱ-15
7 Tooling Setup……. …………………………………………………………….…... …….. Ⅱ-16
8 Machine Operation …………………………………………………………….…... ……. Ⅱ-18
9 Maintenance……………………………………………………………………...….. ….... Ⅱ-22
Part Ⅲ Machine Operation
1 The Explanation of Machines' Figure ……….……..………………….……….. ………. Ⅲ-1-2
2 The Instruction of The Die Installing Operation …………………………..….. ………. Ⅲ-2-2
3 The Instruction of The Machines Operation.……………….…………….. ………....... Ⅲ-3-2
4 The Edit And Input Operations of The System Program……………………. ……….. Ⅲ-4-2
Part Ⅳ Maintenance Instruction
1 Introduce The Machine System…………………………………………….……. ……… Ⅳ-3
2 Maintenance …………………… ……………………………………………..……. ……. Ⅳ-5
3 Lubrication And Maintenance ………………………………………….……..….………. Ⅳ-6
4 Maintenance of The Machines' Structure …..……….………………..……….. ………. Ⅳ-7
5 Selection of The Lubricators ……………………………………………..………………. Ⅳ-7
Part Ⅴ Troubleshooting
1 Excluding Malfunction of the Gauge Type Cutting Machine….. ……………………… Ⅴ-3
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Part Ⅰ Transportation and Installation

Before installing this machine, please read:

" Transportation and Installation ".

Attention !

Why most accidents occur

is because of not following
safety regulations.

The operators should follow all the rules emphasized in this manual
to prevent accidents. If the cutting machine needs maintenance,
operators should report this to the supervisor and stop working on the
machine until the problem is rectified.
This cutting machine should be used for the stated tube capacity.
Never try to cut non-metal material or use the cutting machine to execute
illegal usage. Noncompliance of maintenance, safety and capacity will
void all rights and warranty by JSI.

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Index 1

1 Packing And Transportation ............................................................................................3

1.1 Method of Packing....................................................................................................... 3
1.2 Method of Transportation............................................................................................. 3
1.3 Position........................................................................................................................ 3

2 Installing The Machine .....................................................................................................4

2.1 Cleaning Machines ...................................................................................................... 4
2.2 Operating Environment................................................................................................ 4
2.3 Shock-Absorbing Pads ................................................................................................ 4
2.4 Leveling Machines....................................................................................................... 4
2.5 Toolbox ........................................................................................................................ 4

3 Choice of Oil Sorts ...........................................................................................................5

3.1Hydraulic Oil ................................................................................................................. 5
3.2 Lubrication................................................................................................................... 7

4 Cooling System ................................................................................................................8

4.1 Connecting the Hydraulic System ............................................................................... 8
4.2 Warning! ...................................................................................................................... 8

5 Electrical System..............................................................................................................9
5.1 Warning! ...................................................................................................................... 9
5.2 Connecting the Power ................................................................................................. 9

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1 Packing And Transportation

1.1 Method of Packing

There are two ways to pack in a wooden case or Containerization. Fix the position of the
machines in the inside boxes, and mark the label on the outside boxes.

1.2 Method of Transportation

Read the gross weight from the packing list. Then use a suitable crane or forklift to move the
machine to the preset position. The gross weight of this machine is listed in the Table T.1 of
Technical Document.

1.3 Position
Open the wrap of the material. According to the local law, use suitable steel slings that can
endure the weight of the machine to attach to all of the eyebolts on the cutting machine. Use
the derrick to move the machine to the correct position. Use suitable lifting slings when a crane
is used. If using a forklift truck, use a suitable rated forklift truck.
The diagrams of operating range and hanging position are listed in the Technical Document.
Prepare adequate space before setting the machine.

 The copyright of manual book belongs to CSM. CSM has rights to modify, copy, and use it for
customers.
 No one can modify, copy, and use this manual book without permission from CSM. If someone
violates intellectual property right of this manual book, it will be punished in accordance with
laws.

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2 Installing The Machine

The method that we take on our machine is Complete Assemble Transport. When users begin to
setup the machines initially, please follow the steps as follows:

2.1 Cleaning Machines

Use kerosene or similar fluid. Clean the oil and the rust from the machines. And take the
effective protective method to prevent the accessories of the die and the machines from
damage.

2.2 Operating Environment

We suggest that the machine must be located in a dust-free area. The indoor temperature
range should be between 0°C and 38°C (32°F~99°F). At the bending section of the machine,
provide sufficient space for loading and unloading the tube. The detail information is enclosed
in the technical specification. Please refer to the technical document.

2.3 Shock-Absorbing Pads

For fastening the machine firmly on the floor, users need to drill holes on the floor so that the
machine base can be installed. Further, installing the shock-absorbing pads bought from local
markets could smooth the whole installation. (Vender provides four shock-absorbing pads for
CT series machines.)

2.4 Leveling Machines

Users should apply the leveling bolts and plates (packed in toolbox) to check the level of the
machines to ensure that the machines would not move and shake during the cutting process.
Use the adjusting screws or the proper tools to fix and tighten the slack parts of the machine,
which get loosen from shaking or colliding during the transport process.

2.5 Toolbox
The tools in the toolbox are listed in the Table T.1 of Technical Document.

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3 Choice of Oil Sorts

3.1Hydraulic Oil

3.1.1
Check before pouring oil. Open the lid on the hydraulic oil tank, and check inside the tank to
ensure that it is free of water and rubbish. The hydraulic oil tank capacity of this machine is
listed in the Table T.1 of Technical Document.

3.1.2
We suggest using the high-quality hydraulic oil with wear-resistant additives. The viscosity index
of the oil is 150SUS at 100°F (or VGO-46 ).

Chart 3.1 The Suitable Oil

Brand Production Brand Pour Point(°C) Flash Point(°C)
Bartran 42 -33 222
HP
Bartran 68 -36 208
Rando HD 32 -33 220
CALTEX
Rando HD 68 -30 226
Hydraulic AW Series 46 -18 201
CALUB
Hydraulic AW Series 68 -18 204
46AW -30 242
CPC
68AW -30 246
Visga HP 46 -21 232
ELF
Visga HP 68 -18 242
Nuto H 46 -33 241
ESSO
Nuto H 68 -30 220
Hymax 32R -30 228
KINGUNION
Hymax 68R -27.5 236
Super Hyrandq 32 -25 236
NISSEK
Super Hyrandq 68 -25 258
FG-AW 46 -12 185
PENNZBELL
FG-AW 68 -12 185
Hrdro AW 46 240
SHELL
Hydro AW 68 240

3.1.3
Pump the hydraulic oil through the filter into the tank until the oil covers the top of the sight
gauge in the base. The oil level will drop as the hydraulic system fill when the machine is first
operated. After initial operation, please add the oil to bring the reservoir back to the gauge level
indicator.

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3.1.4 Attention!
Some air may be trapped in the cylinders, which may cause the hydraulic system to have
irregular performance when the machine is operated initially. For the cylinders are air-relievable,
continuous operation through 20 to 30 cycles will automatically relieve air from the hydraulic
system.

3.1.5
Check the hydraulic oil level over 2/3 of the oil sight glass in front of the machine base, and refill
with the suitable hydraulic oil if necessary.

3.1.6
Keep the hydraulic oil reservoir from contamination.

3.1.7
Do not let the hydraulic hoses rub the floor.

3.1.8
In order to achieve the best performance of hydraulic oil, please choose the suitable oil for
different temperature.

Chart 3.2 The Suitable Oil For Different Temperatures

The Range of The The Type And Number of The Oil
Temperature
Viscosity ISO 68 Viscosity ISO 68
25°C Above
China Petroieum AW68, LPS68 BP Energol SHF 68
Viscosity ISO 46 Viscosity ISO 46
10°C ~ 25°C
China Petroieum AW46, LPS46 BP Energol SHF 46
Viscosity ISO 32 Viscosity ISO 32
Under 10°C
China Petroieum AW32, LPS32 BP Energol SHF 32

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3.2 Lubrication

3.2.1
The machine is equipped with an oil-type lubricator. The reservoir of the lubricator was initially
filled at the factory with sliderit #68. Obtain good quality slide way oil and add to the lubricator as
needed. See listing of recommended oils.

3.2.2
Push and release the instant feed button until a noticeable pressure is observed.

3.2.3
Note! The tank is equipped with reverse stop valve so that the oil pumped out can not return. Fill
the lubricator reservoir weekly.

Chart 3.3 Lubrication Equivalents

The Lubricated Suggestive Production Brand
Position of China
Castrol Shell Mobil
The Machine Petroieum
Hyspin AWH Tellua T AW32.46.68
Hydraulic Oil Tank DTE 15
32.46.68 32.46.68 LPS32.46.68
General Oil Magna BD 68 Tonna TX 68 Slideway Oils 68 Vactra No.2
Extreme Pressure Mobilux
General Grease Spheerol AP 2 Calithia EPT 2 EP2
Grease EP2

Chart 3.4 Lubrication Points (Grease Nipples)

Grade of Lubricating Inspection Frequency
Lubrication Point Lubricant Frequency (Operating Hours)
(Operating Hours)
Feed Base Grease 100 500/ 1,000/ 2,000

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4 Cooling System

4.1 Connecting the Hydraulic System

Through the long time operating, the whole hydraulic oil will become hot. The hydraulic
system should be connected to the cooling system and use the cooling fan to reduce the
overall system temperature. It will increase the machine life and prevent cylinder from leaking
oil or other illogical damages. Operator must ensure the hydraulic oil temperature to be kept
below 50°C. The machine is equipped a fan- type cooling system.

Attention! The filter of front cooling system must be cleaned one time a week.

4.2 Warning!
Fill up oil tank with ISO-VG68 hydraulic oil with anti-freezing mixture or to fill up ISO-VG46
hydraulic oil containing anti-freezing mixture for freezing environment.

Attention! All power sources must be turned off as operators clean the parts of the cooling
system. Addition, Don’t operate the cooling system in wet environment.

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5 Electrical System

5.1 Warning!
Check the input electric voltage on the motor and the control cabinet. Make sure they are the
same. Be sure to keep the electric voltage at ___ V 5%.
After connecting the electric power ___ ∮ ___ V ____ HZ, press the “POWER” button
on the electric panel and verify the rotation of the motor is the same as the arrow shown. If
the direction is wrong, please change two phases of the power cable.

5.2 Connecting the Power

5 6 7 4
1. Screen 12.Fix Clamp Base
2. Support 13.Carriage Base
1
3. Motor 14.Cutting Speed Adjustment
4. Main Power Switch (NFB) 15.Cover
5. Power Source Indicator 16.Saw Blade
6. Start Up Button 17.Front Feeder 3
7. Stop Button 2
8. Tank
9. E. M. Stop
10. Pause
11. Start Up (Pedal) 15

13 17
9
16

11

14
10 12
8

Connect the L1, L2, L3 power lines and the machine to the end of the control broad.
Remember! There is an on-off button to control the power. Please use the cable for grounding
in accordance with the local country electric regulation.

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Part Ⅱ Safety Section

The cutting machine
is potentially dangerous if it is not used correctly.
Please observe all information about the use, misuse and hazards
associated with these types of machines.
Before operating the machine,
please read "Safety Section".

Attention !

Why most accidents occur

Is because of not following
safety regulations.

Please read this safety section and the owner’s manual before
tooling setup, operation or maintenance.
The operators should follow all rules emphasized in this handbook
to prevent accidents. If the cutting machine needs maintenance,
operators should report this to the supervisor and stop working this
machine until the problem is rectified.
All factory and national safety precautions, that are in force where
the equipment is located, must be observed at all times. No practices
can be carried out on the machine that would result in unsafe, or that
would endanger the machine operators in any way. The machine must
not be operated in a manner that may cause immediate or long-term
deterioration to the environment.
The maintenance and repair should be executed by the professional
technicians. This is the best safety measure for both human and
machines. If the operators cannot understand the maintenance
procedure, please contact the service engineer from the agent. But do
not try to repair the machines by yourselves.
This cutting machine should be used for the stated tube capacity.
Never try to cut non-metal material or use the machine to execute illegal
usage. Noncompliance of maintenance, safety and capacity will void all
rights and warranty by CSM.

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Index 2

1 Safety Warning Label................................................................................4

1.1 Important Points ...................................................................................4
1.2 Meaning of Label Colors And Basic Sign..............................................5
1.3 The Diagram of Symbols Position ........................................................9
1.4 Potential Hazards .................................................................................9

2 General Information ................................................................................10

2.1 Introduction.........................................................................................10
2.2 Usage of Cutting Machine ..................................................................10
2.3 Prevent Overloading........................................................................... 11
2.4 Develop A Safety Project .................................................................... 11

3 Electrical, Safety Practices ....................................................................12

4 Hydraulics, Safety Practices ..................................................................13

5 Noise Levels ............................................................................................14

6 AC Servo Driver, Safety Practices .........................................................15

6.1 AC Servo Driver..................................................................................15
6.2 Explanation of the Fault Symbols .......................................................15
6.3 Safety Practices..................................................................................15

7 Tooling Setup ..........................................................................................16

7.1 Overview ............................................................................................16
7.2 Tool Setup Safety ...............................................................................16

8 Machine Operation..................................................................................18
8.1 Machines Guards ...............................................................................18
8.2 Safety of Operator ..............................................................................18
8.3 Safe Operating Procedures ................................................................20
8.4 Safety Precautions during Cutting ......................................................21

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9 Maintenance............................................................................................ 22
9.1 Machine Longevity ............................................................................. 22
9.2 Machine Cleanliness .......................................................................... 22
9.3 Machine Upgrades ............................................................................. 22
9.4 Safety of Maintenance ....................................................................... 23

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1 Safety Warning Label

Labels are affixed on the machine and contain brief messages outlining the hazards associated

with that portion of the machine. It is important to note these labels and follow the precautions they

outline.

All signs, nameplates and legends that are attached to the machine are included as following

section with an explanation of their meanings.

Each sign is identified with a unique part number (P87-DW_____) in accordance with Chiao Sheng

Machinery Ltd. Procedures.

All the signs are language-specific for the shipping destination of the machine.

1.1 Important Points

A. The signs should be regularly checked to ensure that they remain clean and visible, and

that their meanings are still appropriate. The signs must not be obstructed in any way.

B. It is the responsibility of operators to report any condition or occurrence that there is a

warning sign or the correct sign is not correctly displayed. The operators must ensure that

the instruction on the warning signs is carried out, or has been complied with before

operating the machine.

C. It is customers’ responsibility to replace any warning signs that become damaged or

illegible at any time during the life cycle of machine. These signs can be provided from

Chiao Sheng Machinery Co., Ltd.

D. Chiao Sheng Machinery Co., Ltd. or their appointed representatives will not be held

responsibility for any accident that occurs on the machine as a result of a mandatory

safety or warning sign not being displayed in the designated position on the machine.

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1.2 Meaning of Label Colors And Basic Sign

1.2.1 Types of Warning Label Colors

Safety Color Meaning or Purpose
Red Stop, Prohibition

Yellow Caution, risk of danger

Blue Mandatory Action

Green Safe Condition

1.2.2 Types of Warning Basic Sign

Basic Signs Explanations

Background color is white. Circular band and cross bar is red.

The symbol is black.
Used in areas of serious danger.

Background color is yellow. Triangular band is black.

The symbol or text is black.
Used mainly to call attention to items during usage (when in
operation.)

Background color is blue. The symbol or text shall be white.

Used mainly to indicate a specific necessary procedure.

Background color is green. The symbol or text is white.

Used in areas of safety.

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1.2.3 Meaning of Symbols

No. Diagram Warning Titles And Meaning

Danger of Pinching Warning Symbol

This symbol is used on warning label for areas at which
there is a danger of serious injury by having a body part
1
pinched between interior moving parts or rotating parts.
These caution items include the safety mechanism
necessary for avoiding a dangerous situation.
P87-DW009

Electric Shock Warning Symbol

There are areas of high voltage inside the control panel
and operating panel and the possibility of electric shock
2
exists.
Anyone touching the interior should have a specialized
knowledge of electronics.
P87-DW001

Danger of Being Caught-Up Warning Symbol

There is a possibility of getting a body part caught up in a
3
gear resulting in serious injury.
Never touch this area during operation.

P87-DW002

Danger of Pinching Warning Symbol

There is a danger of having a body part pinched between
4
interior moving parts resulting serious injury.
Never touch this area during operation.

P87-DW003

Danger of Pinching Warning Symbol

There is a danger of having a body part pinched between
5 interior moving parts or revolving parts resulting in light to
medium injury.
Never touch this area during operation.
P87-DW004

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No. Diagram Warning Titles And Meaning

Use Guard
6 There is a possibility of getting a body part injured.
Use guard in operation.

P87-DW012

Emergency Stop Push Button

7
Push it while in danger. The machinery will stop.

P87-DW016

Hazardous Voltage!
It will shock, hum, or cause death.
8 Do not work in this enclosure unless familiar with these
electrical circuits and safe servicing procedures.

P87-DW005

Confirm The Power

Obey the procedures as following:
9 Before performing maintenance, pad lock main disconnects
switch in off position.

P87-DW006

Moving parts inside openings can crush hands or feet.

10 Do not put hands or feet in openings when the hydraulic
motor is running

P87-DW011

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No. Diagram Warning Titles And Meaning

Prohibit Dismantling
To prevent from injury, the whole hydraulic system and any
11 components of hydraulic system can’t be separated and loose
when the hydraulic motor is running.
Before maintenance, make sure the motor is turned off.

P87-DW007

Space between dies may not be guarded.

To prevent your hands or fingers from injury, must keep your

12 hands out of pinch points as loading material.
Before installing or adjusting dies, make sure motor is turned off.

P87-DW017

Don’t enter the working area.

13

P87-DW014

14 Note the direction of installing saw blade.

P87-DW018

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1.3 The Diagram of Symbols Position

Please refer to Fig T.1 of Technical Document.

1.4 Potential Hazards

The most potentially hazardous areas of the cutting machine are:

1.4.1
The action areas of the carriage and saw blade are especially dangerous.

1.4.2
Die area.

1.4.3
The area of loading and unloading tube is dangerous.

Each of these areas is identified with a corresponding safety label. The labels are shown in
Technical Document, along with a general diagram of a cutting machine. The label areas are
noted on the diagram.

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2 General Information

2.1 Introduction
Most accidents are caused by people failing to follow simple and fundamental safety rules or
precautions. Lack of attention to the instructions in this manual can result in a reduction of
efficiency, accidents and most importantly, personal injury.
As soon as an operator determines that a cutting machine is malfunctioning or needs
maintenance, he should notify his supervisor and discontinue operation of the machine until
the necessary repairs are made.

2.2 Usage of Cutting Machine

2.2.1 The Usage of Cutting Machine
The usage of the cutting machine in a thoughtful and intelligent manner is most importance.
The safety of operators and die setters, as well as the total useful life of the machine is
involved.
The cutting machines, by their nature, are ruggedly built. With proper use and maintenance
the machine will give you many years of service. However, through misuse or accident, the
machine can be severely damaged during a single operational cycle. The misuse of a cutting
machine may not be intentional, but misuse does accelerate the wear and deterioration of
component parts.

2.2.2 The Device of Emergency Touching Control Power Failure

When the machine gets in the emergency situation, you can press the emergency stop button
to be the breaking the action of motor to avoid from the dangerous events. After the damage
has disappeared, you need to restart the motor.

2.2.3 The Location of Emergency Stop Button

A. On the Operating Board
When you press it, the power of all motors and servomotor will be cut.
B. Emergency Stop Pedal (Red)
When you press it, you’ll cut off the power of the lubrication system.

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2.3 Prevent Overloading

Abuse of cutting machine can result in the overloading of the machine’s components.
Overload may be unintentional, it occurs usually, because the operation load is larger than
machine is designed to produce.

2.3.1 The Burden of Operation

Confirm the burden of the operation to prevent the machines from overloading, or it will
influence the using time limit and damage the operators' safety.

2.3.2 To Know The Burden of Cutting

Warning! All detail information about the machine are listed in the Table T.1 of Technical
Document.
Must obey these specifications, or it will cause machines get serious damage and the
company will have an expensive extra maintenance expense.

2.4 Develop A Safety Project

A continuous, supervised project of safety training and instruction can help you minimize the
possibility of injury. The safety project must have leadership and direction from management.
Effective safety training depends on the quality of supervision.
Supervisors must be kept informed in all areas of their job responsibility, including safety.
Supervisors should make daily inspection tours of their departments. Encourage supervisors
to identify, report and correct any safety hazard.
Machine operators should be encouraged to regularly demonstrate and promote their
personal safety awareness.

2.4.1 The Sense of Safety Training

To get the best protective effect, the suitable training is needed. it's necessary to notify the
employees about the personal safe sense, the suitable behavior and some important
regulations including the tooling setters, safe device, operating method, and individual safety.

2.4.2 The Plan of Safety Training

Build up a safe training plan of executing and supervising. Then supervisors can direct and
lead the employees to follow the plan, and make sure the safe training be able to improve the
quality of the management.

2.4.3 The Feedback

To consider the duty of work and safety, supervisors should go around to inspect every work
area everyday to promote the personal safe sense and the safe and dangerous knowledge of
the employees, then reflect the safe situation and improve or deal with it immediately.

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3 Electrical, Safety Practices

Warning Lethal Voltages!

A. The incoming connections on the main isolator terminals will always be live. Do not touch. If an
external auxiliary power socket has been fitted, this will also be live at all times. Only allow
qualified personal to open the electrical enclosures.
B. Before using the machine, the connections at all transformers must be changed to match the
supply voltage of the country where the machine is to be operated.
C. Before any electrical cabinets are opened, the machine must be totally isolated. The main
three-phase power supply to the machine must be turned OFF and clearly marked that
personnel are working on the machine.
D. The main isolator switch must then be locked OFF by using a suitable device. The device must
be of such a design that allows individual padlocks to be inserted: one padlock for each
person working on the machine. It must be impossible for the main isolator to be turned ON
until all padlocks and the locking devices have been removed.
Note that the incoming main power supply will always be live even when the main isolator is
turned OFF.
E. Additional signs should be displayed on the machine and the control cabinet, to warn that
personnel are working on the electrical system.
F. The electrical control cabinet door of the machine must be closed before the main isolator
switch is turned ON to restore power to the machine. Do not leave the door open and attempt
to restore power from inside the cabinet by overriding the switch.
G. The maintenance operators have to take the electrical specialized courses. Please check if
operators have the Circuit Diagrams before the maintenance.
H. Power Supply: ±5% Voltage.
I. The protective device like limit switch couldn’t be shorted or changed.
J. The install operation has to obey the last country electrical law, and be tested completely
according to the law.

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4 Hydraulics, Safety Practices

Warning High Pressure Fluids!

A. This pressure can be measured at a point on the main manifold using the gauge provided.

B. Never, under any circumstance, release any machine hydraulic fittings or assembles from the

system under any pressure. Check to ensure that all pump motors are OFF. When

accumulators are fitted, the system is in a discharged state.

C. Regular checkup must be conducted to all the hydraulic hoses on the machine to ensure that

they remain in a good condition. They should not have any severe abrasions. The machine

must never be used if any hydraulic hoses are split or fractured.

D. All hydraulic components fitted to the machine have been sized (in the case of the hoses

tested) to suit the maximum operating system pressure, as shown on the hydraulic circuits.

Any increase in pressure above the one shown will result in potentially dangerous operating

conditions, and it has to be avoided.

E. Ensure that lubricants and hydraulic oils are nontoxic when purchased from other suppliers,

and only use the products matched with the task.

F. Prolonged contact with mineral oils on bare flesh may remove the natural oil of the skin, and

cause dry out and possible local irritation of the skin. Always wear gloves when handling

hydraulic oil. Never swallow hydraulic oil under any circumstance and if accidentally swallow,

do induce vomiting.

G. For specific safety information regarding oils, please refer to the documentation from the

suppliers. All industrial oil suppliers are obliged to provide full safety information about their

products.

H. Always seek medical advice if oil is swallowed in large quantities.

I. Please clean the oil, which leaved on the ground during maintaining machine or adding the

hydraulic oil.

J. The nullification oil has to handle according to the local law

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5 Noise Levels

The machine is designed and tested to ensure that emission of airborne noise is reduced to the

lowest level, and fall under the acceptable range based on the type of machine.

Noise Degree Circumstance

The noise level read on the machine was measured at the operator
80dBA
workstation.

70dBA This reading was registered with a background noise level.

However, it is strongly recommended that the machine operator and other personnel in the direct

vicinity of the machine adopt the good working practice of wearing suitable ear defenders while the

machine is in operation.

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6 AC Servo Driver, Safety Practices

6.1 AC Servo Driver
The Servo Amplifiers are mounted on the control side of the electric cabinet. One servo
amplifier is fitted to control each AC servomotor on the machine. e.g. feeding and cutting.
Each servo amplifier is monitored by a LED display mounted on the panel of the electrical
cabinet to indicate that if it is active. If the amplifier is not active or is overloaded, then LED
monitoring that particular amplifier will not be illuminated. Under this condition the machine
will not run.
The Operating and setting Instruction manual published by the amplifier manufactures, is
included with the machine documentation. This instruction is therefore limited to immediate
fault diagnosis.

6.2 Explanation of the Fault Symbols

Each amplifier is equipped with a segmented LED display on its front plate, which serves as
status and fault symbols. The explanation of the symbols is enclosed within the technical
specification document.

6.3 Safety Practices

A. Never touch the interior of servo driver while running due to the high-voltage circuit in the
servo driver. Never perform overhaul by yourself, and always make request to our
company or agents appointed by our company.
B. Right after the power is turned off, the circuit may still be charged with high voltage for a
while. If you need to touch the terminals of the terminal board, or the inside of the driver,
please turn off the main power and control power externally and wait for 5 minutes or
more.
C. Please put the cover on the terminal board to prevent electric shock while using the driver.
D. When motor and peripheral units are turned ON, do not touch the driver, for the
temperatures of these units are rising. Specifically, in attending the regenerative resistor,
the temperature of regenerative resistor becomes quite high. Never touch the resistor.
E. As to the driver radiator, the temperatures of regenerative resistor and motor are quite high
for a while, even after shutting off power supply. Do not touch these units.
F. When any alarm has occurred, remove causes to assure safety, then reset alarm and
restart.
(If some alarms occur, read the message number on the display of servo driver that is
mounted on the inside of control box near the back end of the machine. To prevent any
accident, you must handle some processes according to the regulations of Technical
Document at once.)
G. Turn off the power when you do not want to use the machine for a long time.
H. Firmly set and install the equipment to prevent physical injuries caused by insufficient
setting ad installation in case of earthquake.
I. After earthquake, make sure to conduct safety checkup.
J. The inner parameter has been passed the safety test. Don’t change it without any permit.
K. When you want to take apart the servo motor, please turn off the power.
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7 Tooling Setup

7.1 Overview
Tooling setup is an extremely important job. The safety of the operator depends on the proper
execution of this job. The die setters should have a practical working knowledge of cutting
machines, dies and material. Addition, he must know and remember the importance of proper
die adjustment. Tooling must be the proper size for the machine. Overloading a cutting
machine by attempting to cut tubing larger than the rated capacity can result in mechanical
failure and possible injury to operating personnel.
Along with their technical knowledge, die setters must develop a sense of personal safety
awareness. Die setting must be accomplished in a safe manner. All die setters should
recognize the necessity of doing their own job safety as well as providing a safe operation
environment for other.

7.2 Tool Setup Safety

The following precautions are listed as a guide to the development of safe tooling setup
procedures.
A. Never place hands, fingers or any parts of the body within the die area unless the
hydraulic pump motor is turned off.
B. Never install, adjust or remove dies without proper instruction and without first reading and
understanding the tooling instructions in the owner’s manual.
C. Never install, adjust and remove dies or service the machine when the hydraulic pump
motor is turned on.
D. Never wear a necktie, jewelry, or loose clothing while working on or near machinery.
E. Where the tooling is too heavy to be lifted by hand, suitable mechanical methods must be
used. Tooling of said size is provided with a point for screwing in a lifting bolt. Sling or
chains should only be attached to these lifting bolts as these points are determined for
keeping the tooling components stable during lifting.
F. Clean dies before installing. Misalignment caused by dies, chips of metal or other foreign
materials could result in injury to the operator or damage to the machine and dies.
G. The operator must wear personal protective clothing at all times when handling the tooling
components, especially with hands and feet. To avoid the possibility of trapped fingers, do
not physically guide the suspended tooling component onto a location, but preferably use
a suitable hand tool.

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H. Lock the disconnect switch in the off position to prevent the hazard from unauthorized

using of the machine or an unintentional start.

I. Install tooling securely. Be sure bolts are in good condition so that vibration does not allow

dies to move out of position.

J. Use the proper die for the cutting machine’s size to prevent overloading. Never install

worn or damaged dies.

K. After dies are installed, perform all necessary adjustments. Please execute it before

running the machine.

L. Be sure all people clean machines and dies before operating machines.
M. Check all parts of the machine and confirm there are no unwanted components.

N. Observe the machine operation long enough to determine that the machine, dies and

auxiliary equipment are working properly.

O. Report any questionable operation, unusual action, oil leaks, unsafe condition or safety

devices.

P. When changing setting of the cutting machine controls for a different operation, make
certain selector switches are set correctly test cycle to be sure it operates correctly before

cutting materials.

Q. Cutting lubricant that would make the surrounding area slippery would contaminate the
tooling area. Handle the tooling carefully! While it is safe and practical to do so, it is

good practice to plug the end of the tube with absorbent material during cutting, in order to

prevent the cutting lubricant from dripping onto the safety mats and onto the machine,
which can keep the floor from being slippery to reduce the potential hazard to the

operators.

R. When a cutting machine has been in no space operative or left unattended, even for a

brief time, check the setting of all switches before starting the machine.

S. Develop a sense of personal safety awareness. Observe all safety regulations. Learn to

spot hazardous conditions and discuss ways to control them with your supervisor.

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8 Machine Operation
8.1 Machines Guards
It is usually necessary to custom design point-of-operation guards for each application.
The design and manufacture of point-of-operation machine guards adds to the cost of a
machine installation. However, because the machine owner takes responsibility for the
safety of his employees, the additional costs required to properly guard the dies should not
be of primary concern. Covers removed to gain access for service operations must be
replaced before machine operation is resumed.

8.2 Safety of Operator

The following list contains the practices that can minimize the chance of serious operator
injury. Adherence to these practices makes the operator’s job safety and more effective.
Please read and follow each practice carefully.
A. Never operate machine without first reading and understanding the operation
instructions in the owner’s manual.
B. Never place the hands, fingers or any parts of the body within the die area, without
shutting off the hydraulic pump motor.
C. Never wear a necktie, jewelry, or loose clothing when working on or near machinery.
D. At the beginning of each shift and after every break, cycle the machine several times.
Carefully observe the controls to be sure they are functioning properly.
E. Never talk with anyone while operating the machine. If it is necessary to talk, stop the
machine, turn off the motor and step aside until the conversation is completed.
F. Report any questionable operations, unusually actions, oil leaks, unsafe conditions or
improper maintenance to your supervisor.
G. Never attempt to pull a part out of the die with your hands. If a part sticks in the die,
stop the machine and call for your supervisor.
H. Keep all safety guards in place and in good condition.
I. Never reach over, under or around safety guards.
J. Observe machine operation for overloading. Accidental or intentional operation above
the maximum rated torque can result in excessive wear and abuse of the machine
and dies. This can create a hazardous condition.

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K. When turned off the motor, check sight gauges for lubricator level in the lube system.
L. Never stack parts on or near the die area of a cutting machine.
M. Turn off the hydraulic pump motor when no one use the cutting machine. Move the
disconnect switch to OFF to prevent unauthorized use of the machine or an
unintentional start.
N. Clean the machine and inspect it carefully for loose, worn, broken or damaged parts.
O. If two or more people are around the machine during operation. Do make sure that
everyone stays for away from m/c before starting the machine.
P. While operating machine, be sure to position yourself. Don’t come into the scope of
any moving parts. Do not come into the scope during operation.
Q. Develop a personal sense of awareness. Observe all safety regulations. Learn to stop
hazardous conditions and discuss control of them with your supervisor.

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8.3 Safe Operating Procedures

Warning: Possibility of severe injury or entrapment in the machine!

A. The machine must not be operated with any part of the safety equipment inoperative or
ineffective. Neither must the machine be operated if any of the safety devices or safety
guarding have been overridden in any way.
B. Do not operate the machine if a fault is generated during production, which in any way
renders the machine unsafe.
C. The precautions must be taken if any of the following machine malfunctions occurs during
or after cutting materials.
a. If the material can not be released from the tooling, or remains stuck between the tooling
during or after cutting.
b. If the tube is damaged in any way during cutting.
c. If the machine cutting cycle is interrupted or is stopped in any way before a particular
cutting or cutting cycle has been completed. This could result in the tube stuck in the
machine.
D. Emergency, stop the machine as quickly as possible. Report the malfunction immediately
and make all personnel in the vicinity aware that the machine has malfunctioned.
E. If and only if power can be restored safely, switch to Manual mode and attempt to free the
tube from the machine by driving each element of the tooling in turn to the OFF position.
Do not allow anyone to approach the machine during this operation.
F. While you operate the machine controls, never hold the tube yourself, or ask any other
person to hold the tube or any items of the tooling, and then physically try to force the tube
free from the machine
G. If the tube can not be released from the machine by operating in the manual mode, then
under Electrical Safety Approach totally isolate the system and the machine from the
front, and support the necessary parts, and carefully dismantle all the tooling components
to release the tube.
H. After the tube has been released, carry out a full and detailed inspection of the machine,
and report any damage in writing. Also investigate the cause of the malfunction and do not
operate the machine until the fault has been isolated and rectified. If necessary, leave the
machine totally isolated and request service assistance from Chiao Sheng Machinery Co.,
Ltd.
I. Carry out a full and detailed checkup of the safety guarding, after any malfunction has
occurred. Carry out a full startup procedure checkup on the machine, the tooling setup and
the cutting program.

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8.4 Safety Precautions during Cutting

A. Never, under any circumstances, hold the tube while the machine is still in sequence,

even if the sequence has been interrupted and the tube is trapped in the tooling. Do not

carry out any work inside the machine-guarded areas, with the main power switched ON.
B. Operators must communicate!! When the machine is handed over to an operator at

the start of a new shift, a proper handover procedure must be carried out. Always check

the machine configuration and record which options and features on the machine are

active. This is particularly important where Sequencing Options and Sequence Teach

Facilities are active.

C. Never presume or pre-empt what is going to happen during a cutting sequence. If

necessary, select the Manual mode and run the machine through a full cycle before

loading any tube stock.

D. Always carry out a test cut using the Step mode on the “first part” of each new

configuration of a production run. This test cut must be done with the slowest speed.

E. Select the handing speed to produce the component safely and consider all conditions

about the tube before cutting processes. Start slowly and increase the speed and

accelerate gradually.

F. All operators must always be informed on each occasion when the software of cutting

machine is changed. Sufficient training must be given to ensure that all operators become

familiar with safe operating procedures of the machine and with any changes to the

machine sequence and operation.

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9 Maintenance

9.1 Machine Longevity

In order to retain the utility and the safety build into a cutting machine, an effective program of
machine inspection and maintenance must be performed with regularity. Detailed information
concerning this program is presented in the maintenance section of the owner’s manual. It is
difficult to establish life figures for relays, solenoid valves and other electromechanical
components.
Actual life may very, depending upon type of usage, environment conditions and
thoroughness of the preventive maintenance program. Because of wear or improper
maintenance, it is important to realize that a component failure could occur at any time.
However, frequent inspection and a good preventive maintenance program can reduce this
possibility. Immediate replacement of components that are worn or improperly maintained is
imperative.

9.2 Machine Cleanliness

Cleanliness makes any inspection and maintenance program easier. Trouble areas can be
spotted faster on a clean machine and workmen appreciate working in an area where good
housekeeping is practiced.
An occasional coat of paint with a thin film of light oil applied to unpainted finished surfaces
can prevent rusting and help maintain the appearance of the equipment.
It is also important to keep the floor area around the machine clean and free from
obstructions.

9.3 Machine Upgrades

When the machine cannot be practically repaired, order a new machine. Continued operation
of a machine that is worn out is not only unsafe and inefficient, but also is the major cause of
poor die life and unsatisfactory product.
Although the cutting machine becomes old, it is still in good condition that can be updated to
be more efficient such as the latest hydraulic conversion units and new electrical controls.
Users may develop a thorough and objective system to evaluate all cutting machines in
operation, and based on the results of evaluation, users may decide the systems to be
updated, repaired or replaced.

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9.4 Safety of Maintenance

The following list contains precautions that can minimize the chance of serious injury
during maintenance. Read and follow these steps each time you perform maintenance on a
cutting machine.

A. Read the service manual first before maintaining the cutting machine.
B. Never place the hands, fingers or any parts of the body into the potentially hydraulic
areas of the cutting machine unless the hydraulic pump motor is turned off and the
main power disconnect switch is in the OFF position and tagged.
C. Never wear a necktie, jewelry, or loose clothing when working on or near machinery.
D. Hand tools should be carried only in tool boxes or tool belts. Never put hand tools in
pockets or under trouser belt. Never leave tools on or around the machine after you
finish maintenance.
E. Move the power disconnect switch to the off position and lock it out, before performing
maintenance or repair. Make certain that no one can turn it on again without your
knowledge.
F. Make certain that all air, electrical and hydraulically actuated components are
completely assembled and properly attached to the cutting machine before starting the
motor.
G. Use only the proper sizes and types of tooling for the job.
H. After completing machine repairs or maintenance, replace all guards, remove all tools,
start the cutting machine and check for proper operation.
I. Never release the machine for production operation until you are certain that it is
performing correctly.
J. Never leave machines with hydraulic pump motor on.
K. Clean up all oil and grease spills. Leave the entire area around the machine clean.
L. Never paint over any of the safety labels on the machine. Periodically inspect the safety
labels to be sure that they are legible and in place. If any labels are missing or illegible,
contact your supervisor.
M. If the machine does not work normally, turn off the power immediately.
N. Keep area around the machine tidy especially on the floor.
O. Confirm the data before auto process.
P. Do not use any sharp tools to poke the touch screen, to prevent the monitor from
damage.
Q. System pressure should never exceed recommended maximum.

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Part Ⅲ Machine Operation

Before operating the machine,

please read "Machine Operation".

Attention!

Why most accidents occur,

is because of not following
safety regulations.

The operators should follow all rules emphasized in this handbook to

prevent accidents. If the cutting machine needs maintenance, operators
should report this to the supervisor and stop working this machine until
the problem is rectified.
This cutting machine should be used for the stated tube capacity.
Never try to cut nonmetal material or use the cutting machine to execute
illegal usage. Noncompliance of maintenance, safety and capacity will void
all rights and warranty by CSM.

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Index 3

1. The Explanation of Machines’ Figure

2. The Instruction of The Tooling Installing Operation

3. The Instruction of The Machines Operation

4. The Edit And Input Operations of The System Program

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Index 3-1
1 Machine Overview............................................................................................. 2
1.1 Technical Specification .............................................................................. 3
1.2 Explanation of General Machine Diagram................................................. 3
1.3 Explanation of Hydraulic Pressure Adjustment ......................................... 6

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1 Machine Overview
CAUTION
We appreciate your patronage of automatic Low-speed hydraulic circular sawing machine.
This model no. is CT375. In order to help you operate the machine well and get perfect work
result, you are invited to read the manual carefully before operation.

FOREWORD

You can see the picture of Fig-1.1 on the screen. Just press the right side square or the rectangle,
then the digits input column Fig-1.2 will appear on the screen for your data input.

Fig-1.1

It’s the maximum value. If you input It’s the minimum value. If you input
the value that is larger than the the value that is larger than the
maximum value, it will appear an maximum value, it will appear an
“Exceed the limit!!!” signal. “Exceed the limit!!!” signal.

Fig-1.2

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1.1 Technical Specification

Before operating the machine, the user must understand the capacity and the technical
specification of the machine prevent from overloading the machine and resulting in the
damage for both user and machine.
Some capacity and technical specification documents that contain the detail specification of
the machine are enclosed within the Technical Document. If the operators need to take the
reference of the machine, please refer to the Technical Document.

1.2 Explanation of General Machine Diagram

1.2.1 The Body of Machine: As Drawing Fig-1.3.

5 6 7 4
1. Screen 12.Fix Clamp Base
2. Support 13.Carriage Base
1
3. Motor 14.Cutting Speed Adjustment
4. Main Power Switch (NFB) 15.Cover
5. Power Source Indicator 16.Saw Blade
6. Start Up Button 17.Front Feeder 3
7. Stop Button 2
8. Tank
9. E. M. Stop
10. Pause
11. Start Up (Pedal) 15

13 17
9
16

11

14
10 12
8

Fig-1.3

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1.2.2 The Picture of Control Panel

The picture of control panel is as drawing Fig-1.4.The names of the every button are set below
the figure.
The explanation of the detail usage is set at the Chart 1.2.2. Before operating the machine,
operators should read this description first to avoid the damage from the wrong usage.

Fig-1.4

1. Touch Screen 6. Manual Negative Button

2. Function Selection Area 7. Light of Alarm
3. Auto Start Button 8. Alarm Release Button
4. Auto Stop Button 9. Emergency Stop Button
5. Manual Positive Button

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Chart 1.2.2
NO. Name Description
It provides the menus with the operating selection.
When you touch it, it will lead you to other menus or control
1 Touch Screen
various aspects of the machine.

Some buttons will present at this section. These buttons will

Function
change the screen display of the control panel to direct the
2 Selection Area
setup of the different machines. The user should operate as the
(touch-type)
actual circumstance.
While pressing it, you will start an automatic cycle or other
Auto Start operation depending on the currently displayed menu.
3
Button

When you press it, you will stop the automatic cycle.

4 Auto Stop Button

It’s the manual operating button for actions of the machine.

Manual While pressing it, the carriage will move forward until it is
5
Positive Button released.

It’s the manual operating button for actions of the machine.

Manual While pressing it, the carriage will move backward until it is
6
Negative Button released.

When the machine gets the trouble alarm, the light will
twinkle.
7 Light of Alarm

When you relieve of the trouble, you can press this button to
Alarm Release release the alarm warning.
8
Button

While pressing it, you will remove the electrical power

Emergency Stop immediately from the hydraulic and electric motors and stop all
9
Button action of the machine.

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1.3 Explanation of Hydraulic Pressure Adjustment

The machine is based on a hydraulic system with some adjustable knobs that the operators
could adjust the action pressure of every part as the actual operating situation.
The operators must refer to Fig-1.5 to know the position of the adjusting knobs and how to
adjust the adjusting knobs. To operate the machine with appropriate pressure could help the
machine work more smoothly.

1 1. Sol. 43. Saw Head Vertical

Movement Control Valve
2. Sol. 41. Fixed Clamping Die
2 Control Valve
3. Sol. 42. Feeding Clamping Die
Control Valve
3

Fig-1.5

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Index 3-2
2 Instructions of Tooling Installing Operation ................................................... 2
2.1 Installments And Adjustment Tooling......................................................... 2
2.2 Explanation of Installment ......................................................................... 2

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2 Instructions of Tooling Installing Operation

2.1 Installments And Adjustment Tooling

Support Cover

Front Feeder
Carriage

Fig-2.1
Fix Clamp Base

2.2 Explanation of Installment

2.2.1 Carriage Clamp Die
A. Installment
Put the carriage clamp die (1) on the carriage clamp die base (3) and fixed them with
screws (2) such as Fig-2.2.
B. Adjustment
a. Loosen the screws (4) and shift the carriage clamp die base (3) to suitable position.
b. Put the tube and change the operation status to manual mode. Touch \ select the
“ Carriage Clamp Die” square of the screen and press the manual operation button
(positive as Fig- 1.4) to move the carriage clamp die to grip the tube.
c. Fasten the screws (4), and then press the manual operation button (negative as Fig-
1.4) to loose the tube.
d. Then adjust the screw rod as Fig-2.2(5) clockwise about 1/2~1/4 cycle. Fasten the
screws (4) again finally.

2 1

Fig-2.2 5

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2.2.2 Fixed Clamp Die

A. Installment
Put the fixed clamp die (1) on the fixed clamp die base (3) and fasten them with screws (2)
such as Fig-2.3.
B. Adjustment
a. Loosen the screws (4) and shift the fixed clamp die base (3) to suitable position.
b. Put the tube and change the operation status to manual mode. Touch \ select the
“ Fixed Clamp Die” square of the screen and press the manual operation button
(positive as Fig- 1.4) to move the fixed clamp die to grip the tube.
c. Fasten the screws (4), and then press the manual operation button (negative as Fig-
1.4) to loose the tube.
d. Then adjust the screw rod as Fig-2.2(5) clockwise about 1/2~1/4 cycle. Fasten the
screws (4) again finally.

2 1

3
4
5
Fig-2.3

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2.2.3 Saw Blade

A. Installment
a. Loosen the knob (3) and open the safety cover of the saw head, such as Fig-2.4.
b. Loosen the nut (2) and then pull up the brush wheel (1).
c. Installing the elements saw blade (6), fixed cover (4) and nut (5) in sequence finally.
Note: Before installation, please notice the direction of saw blade is correct. Don’t
forget to close the safety cover again.

6 5
Fig-2.3

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2.2.4 Front Feeder Clamp Die (Optional)

A. Installment
Fasten the front feeder clamp die (1) on the front feeder base (4) with screws (2) such as
Fig-2.5.

B. Adjustment
a. Loosen the screws (3) and shift the front feeder base (4) to suitable position.
b. Put the tube and change the operation status to manual mode. Touch \ select the
“ Front Feeder Clamp Die” square of the screen.
c. Press the manual operation button (positive as Fig- 1.4(5)) to move the clamp die to
grip the tube.
d. To complete all adjustment processes after fasten the screws (3).

1 2

3 4
Fig-2.5

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Index 3-3

3 Instructions of Machines Operation ..................................................... 2

3.1 Start Machine ..................................................................................... 2
3.2 Operation In Manual Situation ........................................................... 3
3.3 The Explanation of The Operation In Manual Situation...................... 4
3.4 The Specification Setting In Manual Mode......................................... 6
3.5 Mode Selection In Manual & Auto Situation ....................................... 8

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3 Instructions of Machines Operation

3.1 Start Machine
3.1.1 Operation Step
A. Turn on the main power switch as Fig-1.3(4).
B. Press the “Power ON” button as Fig-1.3(6). (Then the Fig-3.1 will appear on the screen)
C. Main function selection. (At the bottom line of Fig-3.1)
D. Press the function key according to what you need.

Fig-3.1

3.1.2 The Explanation of Icon

Manual Mode: Press this icon to enter the manual mode.

A.

Auto Mode: Press this icon to enter the Auto mode.

B.

Input Program: Edit the working program.

C.

System Configuration: Setting language, password and system

configuration. For agents to modify data and the supervisor
D. administrate.

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3.2 Operation In Manual Situation

** Touch this Icon in Main Menu (as Fig-3.1). Fig-3.2 will show on the screen.

3.2.1 Manual Mode Drawing

1. Coolant
2. The Power of Saw Head
3. The vertical movement of
Saw Head
4. Fixed Clamp Die
5. Carriage Clamp Die
6. Carriage
7. Front Feeder (Option)
8. Front Feeder Clamp Die (Option)

Fig-3.2

3.2.2 The Explanation of Icon

A. Manual mode: Millimeters, Metric units.

Saw specification: Users can note down some information

B. about saw blades in this function.

Mode Setting: Function chooses.

C.

D. Saw Load%: This function shows the load of the saw blade.

Saw Speed (RPM): Users can set the speed of the saw
E.
blade with the function. The unit is RPM in this function.

Carriage Position: In this function, it shows the actual

F.
position of the carriage.

Carriage M.D.I.:
G. Users can set the offset value and speed for the carriage to
control its’ action.

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3.3 The Explanation of The Operation In Manual Situation

3.3.1 Coolant
A. Touch the “Coolant” square of Fig-3.2(1). (It will be dimmed.) Then, cutting machine will
sprinkle coolant on the saw blade to help cutting processes smoothly.
B. The action will be stop as users press the square again.

3.3.2 The Power of Saw Head

A. Touch the square of Fig-3.2(2) and then the screen will show Fig-3.3.
B. If users want to turn on the power of the motor, touch the button about 3
seconds; If not, touch the “EXIT” icon to leave from this function away.
C. The motor will be stop after pressing the square again.

Fig-3.3

3.3.3 The Vertical Movement of Saw Head

A. Touch the square of Fig-3.2(3). (It will be dimmed.)
B. Press the key of control panel (Fig-1.4(5)) to move the saw head up.
C. Press the key of control panel (Fig-1.4(6)) to move the saw head down.

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3.3.4 Fixed Clamp Die

A. Touch the square of Fig-3.2(4). (It will be dimmed.)
B. Press the key of control panel (Fig-1.4(5)), then, the fixed clamp die will grid the tube
tightly.
C. Press the key of control panel (Fig-1.4(6)), and then the fixed clamp die will loose the
tube.

3.3.5 Carriage Clamp Die

A. Touch the square of Fig-3.2(5). (It will be dimmed.)
B. Press the key of control panel (Fig-1.4(5)), then, the carriage clamp die will grid the
tube tightly.
C. Press the key of control panel (Fig-1.4(6)), and then the carriage clamp die will loose
the tube.

3.3.6 Carriage
A. Touch the square of Fig-3.2(6). (It will be dimmed.)
B. Press the key of control panel (Fig-1.4(5)), then, the carriage will move forward.
C. Press the key of control panel (Fig-1.4(6)), the carriage will move backward.

3.3.7 Front Feeder (Option)

A. Touch the square of Fig-3.2(7). (It will be dimmed.)
B. Press the key of control panel (Fig-1.4(5)), then, the front feeder will move forward.
C. Press the key of control panel (Fig-1.4(6)), the front feeder will move backward.

3.3.8 Front Feeder Clamp Die (Option)

A. Touch the square of Fig-3.2(7). (It will be dimmed.)
B. Press the key of control panel (Fig-1.4(5)), then, the front feeder clamp die will grid the
tube tightly.
C. Press the key of control panel (Fig-1.4(6)), the front feeder clamp die will loose the
tube.

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3.4 The Specification Setting In Manual Mode

Fig-3.4

3.4.1 Purpose
Touch the “Saw specification” button from the Fig-3.2 and then the screen will show
Fig-3.4. Users can set some working values in this function.

3.4.2 Operation
Input the correct data one by one to the square in Fig-3.4. The ways how to input are as follows:
A. Touch the square till it gets darker as you wish.
B. Touch the figure square to input correct data.
C. Touch the “Enter” key.

Notice: Please pay attention to the limitation of the input data. The data is displayed at
the top of the figure square. If the input data exceeds limitation, it will appear an “Exceed
the limit!!!” signal. At this time, input correct data again.

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3.4.3 The Explanation of Specification Setting

Saw O.D.(mm): Input the actual diameter of the saw

A. blade. The unit of this item is mm.

Saw Pitch(mm): Input the actual saw pitch into this item.
B. The unit of this item is mm.

Mode Setting: Input the working speed of the saw blade.

C. The unit in the item is R.P.M.

Cutting Load Protect%: Users can set the loading value

D. for cutting process. Some warnings will be provided when
the working loading is bigger then the setting.

E. Solid/ Hollow: Users can select the feature of the tube.

Saw Hardness: Input the value base on the actual

F.
hardness of the working saw blade.

Material Hardness: Input the value base on the actual

G.
hardness of tube.

Cutting Motor Overload Delay: This is a protective

H. function in order to avoid accidents. The cut motor will
delay for setting when the working state is overload.

Optimization: Press the icon after inputting all data in the

I function, then the machine will show the optimum values
of saw tooth number and working speed on the screen.

Back: Press the icon and then the screen will back from
J
Fig-3.4 to Fig-3.2.

Main Frame: Press the icon, the screen will return to

K
Fig-3.1

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3.5 Mode Selection In Manual & Auto Situation

3.5.1 Operating Step

A. Touch the function key “MODE SETTING” of Fig.3-2, then Fig-3.5 will appear on the
screen.
B. Touch the squares to set the operation mode.
C. Touch the button of Fig-3.5 and then the screen shows the next page such as Fig-3.6.
D. Touch the button of Fig-3.6 and then the screen will back to Fig-3.5.

Fig-3.5 Fig-3.6

3.5.2 The Explanation of Icon

A. Cooling Water：Choose the working state
of the cooling water is “Always ON”, “Auto
ON” or “Always OFF”.
B. Cutting Motor： Choose the state of the
cutting motor is “Always ON”, “Auto ON” or
“Always OFF”.
C. Working Cycle：Choose that carry on the
full cycle of program, semi-cycle or one
step’s program.
D. Pedal/ Panel：Users can choose the control
method is “Pedal Start” or “Panel Start”.

E. Material Detect ： Control the function of

“Material Detect” with disable, or enable.

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Index 3-4
4 The Edit And Input Operations of The System Program ............................... 2
4.1 Program The Data – Function Selection ................................................... 2
4.2 File Copy................................................................................................... 3
4.3 The Specification of Tube / Pipe................................................................ 4
4.4 The Specification of Saw Blade................................................................. 5
4.5 The Processing Value Input ...................................................................... 6
4.6 Operation In Automatic Situation............................................................... 7
4.7 Pauses and Release ................................................................................. 8
4.8 Configuration of Controlling System.......................................................... 9
4.9 The Movement's Flow Chart (With Pre-Cutting)...................................... 14
4.10 The Movement's Flow Chart (Without Pre-Cutting) ............................... 15
4.11 Alarm Message And Troubleshooting .................................................... 16

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4 The Edit And Input Operations of The System Program

4.1 Program The Data – Function Selection

A. Touch the function icon “Input Program” and then the Fig-4.1 will appear on the

screen.
B. Input password into Fig-4.1. The default password is “1234”. (Note: If you want to edit

program without password, press the button of mainframe to set the function.

Refer to section 4.8.4)

C. The screen appears Fig-4.2 after input the correct password.
D. The machine provides 500 sets for editing program. Users can press button of
Fig-4.2 to enter the next page. The screen will back as users press the button of
Fig-4.2, either. In addition, Users can input set number into “MemorySet Page” in direct.

Fig-4.1 Fig-4.2

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4.2 File Copy

You can copy a file to another file in this operation. The operation steps are as follows.

A. Touch the “File Copy” button of Fig-4.2.

B. And then Fig-4.3 appears on the screen.

C. Input the numbers of “File Source” and “File Target”.
D. After touch the button , the “File Copy” process will be implemented. If not, please touch
to exit the operation.

Fig-4.3

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4.3 The Specification of Tube / Pipe

A. The screen will appear Fig-4.4 as users decide the program set. Please input the actual data
about tube in sequence. The operation steps are as follows.
a. Touch the square as you wish.
b. Touch the figure square to input correct data.
c. Touch the “Enter” key.
d. All data will be stored when users touch button of Fig-4.4.

e. Touch the button , the machine will delete the program.

Fig-4.4

B. Explanation Function of Tube Specification

A. File Number：The item shows the set number at present.

B. File Name：Users can input file name for the program in editing.

Material Name：Users input the material name of tube in the

C. item.

Material Hardness ： Input the value base on the actual

D. hardness of tube.
Material O.D.：Input the actual diameter of the tube. The unit of
E. this item is mm.

Pre. Cutting Length：Users can input pre-cut length in the item.

F.

Material Length：Input the total length of tube。

G.

H. Solid/ Hollow：Users can select the feature of the tube.

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4.4 The Specification of Saw Blade

A. Touch the button of Fig-4.4, the screen will show Fig-4.5. The operation steps are as

follows.
a. Touch the square as you wish.
b. Touch the figure square to input correct data.
c. Touch the “Enter” key.

d. All data about saw specification would be stored when users touch button of Fig-4.5.

Fig-4.5
B. The Explanation of Specification Setting
Saw O.D.(mm): Input the actual diameter of the saw
blade. The unit of this item is mm. Note: The value can
A. not be “0”.
Saw Pitch(mm): Input the actual saw pitch into this
item. The unit of this item is mm. Note: The value can
B.
not be “0”.
Saw Speed：Input working speed of saw blade. The unit
C. is R.P.M. in the item.

Saw Hardness: Input the value base on the actual

D. hardness of the working saw blade.

Saw Thick：Input the actual thickness of the working saw

E. blade. The unit is mm in the item.
Optimization: Press the button after inputting all data in
the function, then the machine will show the optimum
F. values of saw tooth number and working speed on the
screen.
Tube Specification: Press the button, the screen will
G. back to Fig-4.4.

Program Edit：Press the button, Fig-4.6 will be appeared

H. on the screen. Refer to section 4.5.

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4.5 The Processing Value Input

A. Touch the button of Fig-4.5, and then the Fig-4.6 will show on the screen.

B. Input working data such as “Cutting Length”, “Quantity” and “Speed”.

C. Repeat above process till all working data have been input.
D. The machine will calculate the data of “Material Total Length” and “Material Remain Length” to
itself base on your working setting.

E. If you want to reset all working data, press the button of Fig-4.6, then all data will be
cleaned away.

Fig-4.6

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4.6 Operation In Automatic Situation

4.6.1 Explanation of Automatic operation

A. Touch the “Auto Mode” button from mainframe and then Fig-4.7 shows on the screen.
B. “File Name” shows working program as you wish after input the file number into “Input Cut
Data Set NO.”.
C. Select and touch the function if cut process with pre-cutting. (Refer to section 4.9 and 4.10)

D. Touch “Mode Set” button of Fig-4.7, users can control every working action in Auto

Mode with this function. The setting method is as same as section 3.5.

E. Press and hold the button on 3 seconds, the cutting machine will start working

processes in Auto Mode right now.

Fig-4.7

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4.7 Pauses and Release

When the cutting machine is running in Auto Mode, the operator wants to pause or stop the
hydraulic system. It has two ways as follows.
4.7.1 Pause
The button position is located at the control panel (Fig-1.4 ) ) and on the top of pedal
switch (Label SB 17). When you press the “pause”, the cutting machine pauses all the actions.
The message Fig-4.8 will show on the screen immediately. If the operator needs to release the

button, press the button and hold on 3 seconds. Then the cutting machine will carry on

the next step working again. Note: The operator must confirm that there is nobody on the
working area before the cutting machine restarting.

Fig-4.8
4.7.2 Emergency Stop
The button position is located at the control panel (Fig-1.4 (9)) and the red pedal stop
(Fig-1.3(10)). When you press any “Emergency Stop”, the hydraulic power will be interrupted and
the cutting machine stops completely. Then the screen will show some message to remind the
operator that the hydraulic was cut off. After the operator release the “Emergency Stop”, Fig-4.9
will show on the screen. If you want to restart the working processes again, please operating with
the instructions on the Fig-4.9. Note: The operator must confirm that there is nobody on the
working area before the cutting machine restarting.

Fig-4.9

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4.8 Configuration of Controlling System

4.8.1 The Frame of System Configuration

A. Touch the “System Configuration” button from mainframe and then the screen will

show Fig-4.10.

Fig-4.10

B. Explanation the Squares of System Configuration

Unit：Choose the working unit with “mm” or “Inch”.

A.

Language：Choose the operation language with “Chinese” or

“English”.
B.
Saw Blade State：The cutting machine provides 4 sets for
users note some information about saw blade into this
C. function. Refer to section 4.8.6.
Screen Adjustment：Users can adjust the states of screen
D. with this function.
I/O Detection：All I/O statuses in the cutting machine will
E. shows on the screen with the function.
Mainframe：The screen will back to Fig-3.1 as users press the
F. button.

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4.8.2 System Information

A. Key in the password in the Fig-4.10. (The default password is “12345678”) and then the screen
shows as Fig-4.11.
B. Users can know some information about the machine system with this function, such as “Screen
Software Version”, “Total Running Time”, “Total Cutting Times” and so on.

C. Users can set cutting machine’s time and date as press the “Time Set” button from

Fig-4.11.

Fig-4.11

4.8.3 Delay Setting

A. Press the “Delay Set” button in Fig-4.11, and then Fig-4.12 shows on the screen.

Fig-4.12

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B. Explanation the Squares of Delay Setting

Fix Clamper Close Timer：Users can set the fix clamper close
A. timer with this function.
Feeder Clamper Close Timer：Users can set the feeder
B. clamper close timer with this function.

Cut Motor Acceleration：Users can set the acceleration of cut

C. motor with this function.
Cutting Head Low Limit Timer：Users can set the low limit
D. timer of cutting head with this function.
Fix Clamper Open Timer：Users can set the fix clamper open
E. timer with this function.
Feeder Clamper Open Timer：Users can set the feeder
F. clamper open timer with this function.
Cut Motor Deceleration：Users can set the deceleration of cut
G. motor with this function.
Front Clamper Close Timer(Option)：Users can set the front
clamper close timer with this function. If the cutting
H. machine has no front clamper, users have no need to set this
function.
Front Clamper Open Timer(Option)：Users can set the front
clamper open timer with this function. If the cutting
I. machine has no front clamper, users have no need to set this
function.
System Configuration：The screen backs to Fig-4.11 as users
J. press the button. Refer to section 4.8.2.
Numerical Setting：The screen shows Fig-4.11 as users press the
K. button. Refer to section 4.8.4.
Default Setting：Press the button and then all data of delay
L. setting will return to default setting.

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4.8.4 Numerical Setting

A. Press the “Numerical Setting” button in Fig-4.12, then Fig-4.13 will appear on the screen.

Fig-4.13

B. Explanation Function of Numerical Setting

Config. Password: Users can set password for

A. system configuration.
Data I/P Password: Users can set password for
B. program editing.
Password Enable/ Disable: If users want to edit
working program without password, please select
C.
and mark “Disable”.
Front Feeder Stroke (Option): Input value of front
feeder stroke with the item. If the cutting
D. machine has no front feeder, users have no need
to set this function.
Carriage Front Limit：Users can set the front limit
E. position of carriage in the function.
Carriage Rear Limit：Users can set the rear limit
F. position of carriage in the function.
Cycle Start (1 step)/ (2 step)：This is a protective
function in order to avoid accidents. All parts of the
G. machine will return to reset condition when starting
cut processes in auto mode. Using “2 step” can
avoid accidents for operators.
Default Setting ： Press the button and then all
H. numerical setting data will return to default setting.

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4.8.5 Alarm Record

Press the “Alarm Record” button of Fig-4.11, the Fig-4.14 will show on the screen at once.

Users know some alarm information about the machine, such as alarm date, time and alarm code.
Alarm codes help us to erase troubles in the cutting machine. There are 5 records for marking
alarm information lately down in the cutting machine.

Fig-4.14

4.8.6 The History Record of Saw Blade

Press the button of Fig-4.10, the Fig-4.15 will show on the screen. Users can note some

data about saw blades in this item. The function helps operators to know the statuses of working
saw blade. In addition, the machine automatic reminds operators when the saw blade must be
changed base on these records. There are 4 records for marking saw blade data down in the

machine. If you want to update the records, press the button in Fig-4.15.

Fig-4.15

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4.9 The Movement's Flow Chart (With Pre-Cutting)

Put Pipe \ Tube

Press The Button of Control Plane
or StartUP From Pedal (As Mode Setting)
Carriage Clamper Close

Feed
Fixed Clamper grid tube

Carriage Clamper open

Cutting Carriage Clamper Close Carriage Clamper Close

Fixed Clamper open Fixed Clamper open
Carriage Clamper Close

Fixed Clamper open Feed Feed

Feed Fixed Clamper grid tube Fixed Clamper grid tube

Fixed Clamper grid tube Carriage Clamper open Carriage Clamper open
Carriage Clamper open Cutting Cutting

Cutting

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4.10 The Movement's Flow Chart (Without Pre-Cutting)

Press The Button of Control Plane

or StartUP From Pedal (As Mode Setting)

Saw Head Down

Put Tube and Meet Saw Blade

Press The Button of Control Plane

or StartUP From Pedal (As Mode Setting)

Fixed Clamper grid tube

Saw Head Up

Press The Button of Control Plane

or StartUP From Pedal (As Mode Setting)

Carriage Clamper Close

Fixed Clamper Open

Feed

Fixed Clamper Close

Carriage Clamper Open

Cutting Carriage Clamper Close Carriage Clamper Close

Carriage Clamper Close Fixed Clamper Open Fixed Clamper Open

Fixed Clamper Open Feed Feed

Feed Fixed Clamper Close Fixed Clamper Close

Fixed Clamper Close Carriage Clamper Open Carriage Clamper Open

Carriage Clamper Open Cutting Cutting

Cutting

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4.11 Alarm Message And Troubleshooting

4.11.1 Alarm Message

When you execute the illogical and error operation, the machine will make the bell alarm. Then, the
malfunction reason will appear on the screen and teach you how to solve this problem such as
Fig-4.15.

Fig-4.15

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4.11.2 Troubleshooting
When the machine starts to operate, the malfunction reason will appear on the screen and
advise operators where it is out of order as some trouble happenings.
The following table indicates that how to solve the problem and the statements of
troubleshooting.

NO Trouble Point Solutions

1 Fnt. Feeder Fwr.sensor Check the cylinder of Fnt. feeder move normally? If not, please
(Snr-72) or Hydraulic check valve (SOL-47), if yes, check the sensor (SNR-72).
Valve (Sol-47) out of order
2 Fnt. Feeder Fwr.sensor Check the cylinder of Fnt. feeder move normally? If not, please
(Snr-73) or Hydraulic check valve (SOL-47), if yes, check the sensor (SNR-73).
Valve (Sol-47) out of order
3 Cut head move down Check the cylinder of Cut Head move normally? If not, please
sensor (Snr-68) or check valve (SOL-43), if yes, check the sensor (SNR-68).
Hydraulic Valve (Sol-43)
out of order
4 Cut head move up sensor Check the cylinder of Cut Head move normally? If not, please
(Snr-69) or check valve (SOL-43), if yes, check the sensor (SNR-69).
Hydraulic Valve (Sol-43)
out of order
5 E.M. Stop Button be Release emergency stop button and press ALARM CANCEL
active button.
Hydraulic motor is overload, please check the motor and
10 Hydraulic Motor over load
voltage of power source.
Servo motor is overload, please check the motor and voltage of
11 Servo Motor over load
power source.
24V D.C. power Check the Fuse is melted, If yes, change the same size fuse,
12
abnormally if the fuse is melted often, please contact service person.
Feeder servo motor driver Please check the display of feeding servo driver (in the control
13
abnormally. box), and contact service engineer.
Feeding distance over Check the value of work data, is over limit, or limit switch is in
14
Fnt. Limit correct position
Feeding distance over Check the value of work data, is over limit, or limit switch is in
15
Rear. Limit correct position

Part III Machine Operation CT Series

 Doc. No. CE305-TX Doc. Page IV-1
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

Part Ⅳ Maintenance Instruction

Before maintaining the machine,

please read "Maintenance Instruction".

Attention!

Why most accidents occur,

is because of not following
safety regulations.

To keep the cutting machine working normally and safely, it is necessary

to maintain the machine periodically and build an effective maintenance plan
according to the user application, and environment.
The operators should follow all recommendations in this handbook to
avoid accidents. If the cutting machine needs maintenance, operators should
report this to the supervisor and stop working this machine until the problem
is rectified.
The maintenance and the repair of the machine should be executed only
by professional technicians. This is the safest way for both human and
machines. If the operators cannot understand the maintenance procedure,
please contact the service engineers from the agent. But do not try to repair
the machines by yourselves.
This cutting machine must be used for the stated tube capacity. Never try
to cut non-metal material or use the machine to execute illegal usage.
Noncompliance of maintenance, safety and capacity will void all rights and
warranty from CSM.

Part IV Maintenance Instruction CT Series

 Doc. No. CE305-TX Doc. Page IV-2
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

Index 4

1 INTRODUCTION OF MACHINE SYSTEMS ......................................................................... 3

1.1 HYDRAULIC OIL SYSTEM .................................................................................................... 3
1.2 ELECTRICAL SYSTEM ......................................................................................................... 4
1.3 COOLING SYSTEM.............................................................................................................. 4

2 MAINTENANCE .................................................................................................................... 5

3 LUBRICATION AND MAINTENANCE .................................................................................. 6

3.1 LUBRICATION PERIOD ......................................................................................................... 6
3.2 HYDRAULIC OIL ................................................................................................................. 6

4 MAINTENANCE OF MACHINES' STRUCTURE .................................................................. 7

5 SELECTION OF LUBRICANTS............................................................................................ 7

Part IV Maintenance Instruction CT Series

 Doc. No. CE305-TX Doc. Page IV-3
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

1 Introduction of Machine Systems

The automatic cutting machine, which is produced by Chiao Sheng Machinery Co., Ltd. is a
hydraulic operated machine. It is designed to cut different kinds of material and tubing ( i.e. steel
tube and non-steel tube ) very efficiently and precisely under the different modes. If you need
special dies like square tube, oval tube, rectangle tube, and other shape sections, please inquire
and contact CSM.
The main systems of the cutting machine are introduced as follows:

1.1 Hydraulic Oil System

1.2.1
The hydraulic oil is sent through the vane-driven hydraulic pump.

1.2.2
The device and function of the hydraulic oil system are as follows:
A. Hydraulic Pump
It is fitted on the machine oil tank. There is a filter setup on the oil-bore to avoid dust and
metal particles falling into the oil tank.
B. Power Motor
It is positioned outside the tank. The main shaft connects the electrical motor and the
hydraulic pump.
C. Components of Hydraulic System
For example, the relief valve can be adjusted and set to the highest hydraulic pressure for
protecting the pump from overload.

Part IV Maintenance Instruction CT Series

 Doc. No. CE305-TX Doc. Page IV-4
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

1.2 Electrical System

1.2.1 Correct Electrical Power Cable Supply

Power supply of the correct electrical wiring is essential for electrical machines. Before
connecting the electrical power, please use a proper electrical wire gauge in accordance with
the reference main electric voltage shown on the motor plate. The reference main electric
voltage is also listed in the Table T.1 of Technical Document.

1.2.2 Function of Electrical System

Use the "On" and "OFF" buttons to start the motor. The setup device of the motor is
electromagnetic which can increase the starting capability of the motor. The inner
temperature-overload relay protects the motor coil from extreme high temperature. (The
control power of the electromagnetic valve is 24 DC volt.)

1.3 Cooling System

1.3.1
The temperature of hydraulic oil increases in direct proportion to the machine operating time.
Whole hydraulic system of the cutting machine has to be connected to an air-cooling system
to stabilize the oil temperature. Said system will prolong the life of oil and hydraulic system.

1.3.2
The cooling system can keep the temperature of the hydraulic oil at 55°C, which would
prolong the life of the components of hydraulic system, and further keep the accuracy of
cutting actions.

Part IV Maintenance Instruction CT Series

 Doc. No. CE305-TX Doc. Page IV-5
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

2 Maintenance

2.1 Before maintaining the machines, please read "The Maintenance Instruction" first.

2.2 Before switching off the hydraulic pump, do not put your hands, fingers, or any parts of your
body into the cutting machine.

2.3 While you are near the machines in operation, do not wear ties, jewelry slack clothes etc.

2.4 To avoid damage from using the machines without the permission or turning on the switch by
accident, turn off the electric power and lock the switch on the "OFF" position.

2.5 Use the gauge die to execute the adjustment, machine testing, and die testing.

2.6 Do not leave the machine unattended while the pump is active.

2.7 Put small tools into the toolbox or the tool-waist-pocket. After maintenance, do not leave any
tools around the machine.

2.8 Before starting up the machines, check if all components of compressed air, electricity, and
the hydraulic system are connected properly. After confirming the power ampere matching
the requirement, the machine can then be started.

2.9 After completion of maintenance, identify and confirm the related parameters and put away all
tools. Then, start the cutting machine and make sure it works smoothly.

2.10 Clean out all debris, and clean the area around the machines every day.

2.11 When you repaint the machines, do not cover the safety labels attached to the machines.
Periodically inspect if those labels are visible and recognizable. If not, please replace with
new ones by contacting the supplier.

Part IV Maintenance Instruction CT Series

 Doc. No. CE305-TX Doc. Page IV-6
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

3 Lubrication And Maintenance

3.1 Lubrication Period
3.1.1
The correct and periodical lubrication can extend the life of machines. If machines are
operated continuously, they need to be lubricated once every eight hours. If machines are
operated discontinuously, they need to be lubricated once every week or the accumulative
working time is eight hours (whichever comes first). Every time when you lubricate machines,
please be aware of the following items:

3.1.2 Main Points of Using Lubricants

A. Before lubrication, please wipe the machines with the clean mop to avoid the dirt or dust
dropping into the shaft.
B. After continuously working on the machines for eight hours, it is suggested to use the
high-quality lubricant L-2 or multi-purpose lubricant L-2 to paint or fill up the parts as
needed.
C. The lubricated points are noted in Technical Document.

3.2 Hydraulic Oil

3.2.1
We suggest using the following high-quality hydraulic oil which almost include anti-wear
additives. The viscosity index of the oil is 150SUS at 100°F(or VGO-46 ).

Chart 3.1 The Suitable Oil For Different Temperatures

The Range of The The Type And Number of The Oil
Temperature
Viscosity ISO 68 Viscosity ISO 68
25°C Above
China Petroieum AW68, LPS68 BP Energol SHF 68
Viscosity ISO 46 Viscosity ISO 68
10°C ~ 25°C
China Petroieum AW46, LPS46 BP Energol SHF 68
Viscosity ISO 32 Viscosity ISO 68
Under 10°C
China Petroieum AW32, LPS32 BP Energol SHF 68

3.2.2
Everyday the operators should inspect the change of the oil volume. Confirm and keep the oil
surface at the 2/3 position of the indicator. If it needs to add the oil, please confirm the oil sort
and use the same sort of the oil. Then, delivery the oil through the filter into the hydraulic
system.

3.2.3
If as working the machine for half year to one year you find that the oil is polluted or
overheated emulsification, please drain off the oil in the hydraulic tank clearly. And then, wash
or change the filter or the filter net. At last, add the clear hydraulic oil.

Part IV Maintenance Instruction CT Series

 Doc. No. CE305-TX Doc. Page IV-7
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

4 Maintenance of Machines' Structure

Chart 4.1 The Chart of Periodic Inspection And Maintenance of The Machines
Per Per Per Half
No Note Item
Daily Week Month Year
1 Inspect the function of the supply of the hydraulic system. X
2 Inspect the function of the limit switch and adjust it to the most X
suitable position.
3 Inspect if the screw nuts and the bolts are fixed and tight. X
4 Inspect if the high pressed hydraulic tubes are worn or leak. X
5 Inspect if the hydraulic oil flows smoothly. X
6 Inspect the distance between sensors and objects.(4 ~ 5 mm) X
7 Inspect the action of the cylinders. X
8 Inspect if the machine base are worn or lack of lubricating. X
9 Inspect the idle gear and rod shaft. X
10 Inspect the suitable pressure of the system. X
11 Inspect the base of the machines. X
12 Inspect if cylinders are leaking. X
13 Inspect the main rod of all cylinders. X

5 Selection of Lubricants
Some lubricants suggested are listed as Chart 5.1. The diagrams that describe the lubricated
positions in machines in detail are enclosed within the Technical Document. Before lubricating
machines, operators must refer to the Technical Document.

Chart 5.1 Lubrication Equivalents

Lubricated Suggestive Production Brand
Position of China
Castrol Shell Mobil
Machines Petroieum
Hyspin AWH Tellua T AW32.46.68
Hydraulic Oil Tank
32.46.68 32.46.68 LPS32.46.68 DTE 15

General Oil Magna BD 68 Tonna TX 68 Slideway Oils 68 Vactra

No.2
Extreme Pressure Mobilux
General Grease Spheerol AP 2 Calithia EPT 2 Grease EP2 EP2

Part IV Maintenance Instruction CT Series

 Doc. No. CE305-TX Doc. Page V-1
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

Part Ⅴ Troubleshooting

After the operators have

finished the setup and all adjustments,
they can start operating machine.
Before executing the operation,
please read" Troubleshooting".

Attention!

Why most accidents occur,

Is because of not following
safety regulations.

To read "Troubleshooting" can predict, prevent, or improve the

problems, which may occur during the operation cycle.
Maintenance and repair of the cutting machine should be executed
by professional technicians. This is the safest way for people and
machines. If the operators cannot understand the maintenance
procedure, please contact the service engineer from the agents. Do not
try to repair the machines by yourselves.
This cutting machine should be used for the stated tube capacity.
Never try to cut non-metal material or use the machine to execute illegal
application. Noncompliance of maintenance, safety and capacity will
void all rights and warranty by CSM.

Part V Troubleshooting CT Series

 Doc. No. CE305-TX Doc. Page V-2
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

Index 5

1. EXCLUDING MALFUNCTION OF THE GAUGE TYPE MACHINE .................................. 3

1.1 MACHINE STARTUP AND TEST ............................................................................................. 3
1.2 HYDRAULIC PUMP .............................................................................................................. 4

Part V Troubleshooting CT Series

 Doc. No. CE305-TX Doc. Page V-3
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

1. Excluding Malfunction of the Gauge Type Machine

1.1 Machine Startup and Test

Problems Causes Solutions
The pump 1. The electric power is 1. Recheck the power source and push the
and the driving cut off or supply voltage ‘START’ button if there is no problems.
motor can not is cut off spontaneously.
be started or is 2.Motor is overloaded and 2. Check the overload protection switch. Restart
abruptly the overload protection the machine in three minutes. If the switch trips
stopped in switch trips. again, it indicates that wiring or electrical
operation. elements are out of order. Only restart the
machine after all the malfunctions are cleared.
3. The electromagnetic 3. Change the coils or the electromagnetic
contact is overloaded to contacts.
trip the coils.
4. The control loop fuse is 4. Inspect the broken points correctly.
burned out. After repairing/replacing the fuse, start the
machine again.
5. The safety switch does 5. Replace the safety switch.
not function or trips.
6.The transformer is 6. Replace the transformer.
burned or broken.
7.The spontaneous 7. Improve the power source or install the power
voltage is unstable stabilizing device
(over 10%).
Machine does 1.The solenoid valve is 1. Clean up the valve to remove blockage. Replace
not work even broken. with a new valve, if there are leaks
with good 2. Inspect the wiring and check the input
driving force direct-current voltage (24V). If the coil is burned,
from pump replace it.
and driving 3. Tear off the valve to inspect if the spring or the
motor oil ring is broken, change or repair them if
necessary.
4. Check the light on the valve. If it is broken, test
the circuit broad and repair it.
While the 1. Check the oil level 1. When it is too low, add the hydraulic oil.
motor is indication.
working, the 2. Check if the oil filter is 2. Clean or change the oil filter.
action of the jammed. After draining out the oil in the tank, clean the
machine is very tank and install the oil filter net.
slow. Then, add the new hydraulic oil.
3. The hydraulic pump is 3. Refer to the troubleshooting of the hydraulic
broken. pump.
4. Check if the hydraulic 4. Use the pressure control bar to adjust the
pressure is too high. pressure back to normal.
5. Check if the hydraulic 5. Clean or replace the hydraulic relief valve.
relief valve is broken.
Table 1.1 Problems and Solutions

Part V Troubleshooting CT Series

 Doc. No. CE305-TX Doc. Page V-4
Issue Date 2010/01 Chiao Sheng Machinery Co., Ltd. Version V1.200

1.2 Hydraulic Pump

Problems Causes Solutions

The pump 1. The oil level of the tank is 1. Add the hydraulic oil.
could not deliver too low.
the rated 2. The oil filter is jammed. 2.Clean or change the oil filter.
pressure. After draining out the clean oil in the tank,
cleanse the tank and install a new oil filter.
Then, add the new hydraulic oil.
3. The viscosity of the 3.Choose the suitable oil according to the
hydraulic oil is too high and work environment temperature
it causes the pump cannot
push out the oil.
While the 1. The oil sealing of pump is 1. Use the 500 Inch/Pond torque to tighten
pump is running, broken. the flange jointer evenly (do not
Abnormal noise (The air enters when the oil over-tighten).
is generated or is sucked into the pump.) After tightening the flanges, please change
the oil pressure is the oil sealing if the noise still exists or the
too low. hydraulic pressure is not enough.
2. The suction lines of the 2. Fill in the hydraulic oil from the suction
pump are leaking. side for searching the leakage location.
Tighten or replace the leakage parts.
Table 1.2 Problems and Solutions

Part V Troubleshooting CT Series